Aluminum

[Bob Savage]

I may have an opportunity to do some aluminum faceplates for a guitar amplification company, but to date have not done any metal work on the CNC.

These are thicker than sheet metal (.188") and will require some fine details for the tone and volume controls, company name/logo, etc. There are also several profiled vents in the faceplate.

So, where would I start? Obviously I would need a misting system unless I wanted to stand there with a spray bottle (which I don't). I don't have a vaccum table so I'd just find open areas to screw the sheet to the table and I learned last week while hanging with the Camaster crew that dust collection should be off so I don't accidentally start a fire in my chip bin.

But what other considerations are there? I would *really* like to get this job because it could lead to other sizeable jobs since this is a fairly well known MFG that sells via Musicians Friend, Guitar Center, etc.

Also, and I've posted this on the Aspire forum, but how would you approach doing a 1/2" 100 degree countersink into a 1/4" hole on this material? I could do it by hand since I have adjustable countersink sleeves but if it could be done on the machine that would be ideal.

Edit: Doh! Nice job spelling aluminum...

[Scott Shepherd]

Bob, there was a post by Paul Phillips (I think) some time ago about cutting aluminum. It's very detailed and will answer all your questions. I cut it on a weekly basis. haven't had the first issue since I followed his advice. I do admit, I baby it more than I should, but for the stuff I do, saving 1 minute or even 10 minutes doesn't make much difference to me.

[Bob Savage]

Bob, there was a post by Paul Phillips (I think) some time ago about cutting aluminum. It's very detailed and will answer all your questions. I cut it on a weekly basis. haven't had the first issue since I followed his advice. I do admit, I baby it more than I should, but for the stuff I do, saving 1 minute or even 10 minutes doesn't make much difference to me.

Found it, thank you!

[Bob Savage]

Bob, there was a post by Paul Phillips (I think) some time ago about cutting aluminum. It's very detailed and will answer all your questions. I cut it on a weekly basis. haven't had the first issue since I followed his advice. I do admit, I baby it more than I should, but for the stuff I do, saving 1 minute or even 10 minutes doesn't make much difference to me.

Scott,

Did you buy the same misting system Paul uses? I know it's worth it but was hoping to spend a little less money than what the Trico MD 1200 costs.

[Dan Hintz]

I picked up the Kool Mist PORTaMIST kit...

[Bruce Boone]

I also used a Kool Mist system when I first started machining titanium. A lot less messy than spray bottles or flood coolant.

[Scott Shepherd]

Bob, I didn't. I bought a Kool Mist system. Some people swear they don't want all that fog of mist around, but that coolant he recommended takes very little. You can't see it coming out, and it leaves very little trace, it's so little coming out. Of course I have cranked it up and fogged my entire shop up a time or two, but you don't need to. If I had to do it over again, I'd upgrade my spray mist system a notch or two. Mine is kind of fiddly and I don't have a ton of control over it. If I leave it attached to the machine, it will siphon all the coolant out of my container, so every time I stop using it, I have to completely unhook it, which is a pain. A better system would have the ability to turn off the coolant flow. On mine, the only setting is air, and that determines how much coolant comes out. More air, more coolant.

But that coolant is excellent.

[Scott Shepherd]

One more thing- don't cheap out on the coolant. The stuff that came with my kool mist destroyed my vacuum table. The $100 a gallon coolant he recommended does not do anything to the table.

[Dan Hintz]

Steve,

The coolant supply line is a pretty supple rubber line, if memory serves... have you thought about just pinching it off with one of those binder clips (or similar)?

[Bob Savage]

Guys, thanks for the advise.

I haven't tried aluminum partly because I don't want the coolant mess so I'll be buying the expensive synthetic stuff for sure.

[Bob Savage]

So I'm checking out the Kool Mist systems. How did you guys mount the coolant bucket? Is it on your gantry? The stock tubing is very short.

Also, thank you to whichever admin fixed the terrible spelling of aluminum in the subject.

[Bruce Boone]

Mine just sat on my table, as I had the room. I just wound a copper wire around the tip and fashioned a hook and hung it up higher than the tank when the job was done.

[Keith Outten]

There is an air line cooler available that might be worth taking a look at if you don't like the idea of using a liquid coolant. I don't know anything about this product, just that it exists.
.

[Dan Hintz]

Keith,

The air line coolers (vortex coolers) require a boatload of air... like 15CFM at 120psi. If you have the compressor for it (like a scroll type), it's a great tool.

[Scott Shepherd]

Right on Dan, those air coolers will go through more air than most of us can supply.

There's a place on our gantry that the 1 gallon of coolant fits well. I just sit it there, run a bungee cord around it so it doesn't fall off and we're off to the races. I've got a concept for a small container that would stay mounted, but just haven't had the time to make it.