Working With Aluminum #5
Tabs
- Tool: Generic 2 flute 1/8" up spiral bits
- Stock: 1/8" thick 6061 Aluminum
- Lubrication: Trend Tool and Bit Cleaner
When machining a part out of aluminum, you really need to watch your tabs. There is a lot more force on the part then machining plastic or wood. Make your tabs too small or thin and you will loose your part.
DOC: .01"
RPM: 24000
Cut Feed: 40IPM
Finish Feed 20IPM
Both cut and finish passes use a .25" ramp.
I'm machining this part out of 1/4" aluminum, but using the same tabs I used on the previous 1/8" stock. They just didn't hold up.
Also keep in mind, if you decide to go a little deeper than the stock is thick, you will loose some of your tab thickness as well. Its a fine line to walk with tabs. Too large and you have a lot of cleanup. Too thin and you throw the part.
Your CAM software is where you add your tabs. I used Vcarve Pro here and was able to create what they call 3D tabs. With this kind of tab, the tab thickness is thinner at the top so the tool is ramped. The creates a smoother part with less cleanup, but has a smaller sweat spot than just adding normal square tabs.
Working With Aluminum #6
Pilot Pockets
- Tool: Generic 2 flute 1/8" up spiral bits
- Stock: 1/8" thick 6061 Aluminum
- Lubrication: Trend Tool and Bit Cleaner
What the heck is a pilot pocket?
Often I will be machining a part and need to create a hole that is smaller then the bit I am using. Many times, I will just make a small pocket where I want the hole. I can then drill the hole the correct size latter.
This can sometimes be the only answer when working with thicker aluminum and small holes.
DOC: .01"
RPM: 24000
Cut Feed: 40IPM
Finish Feed 20IPM
Both cut and finish passes use a .25" ramp.
Here I am adding 4 small pockets that will later be drilled with a .120 drill bit and then tapped.
Oh, check out the parts I am making. For a prototype drag knife I am working on.
