Best tool for cutting a square 30mm hole in 1/8" thick aluminium.

[knighty]

30mm hole in 40mm box means you only have 5mm each side... and you lose a bit to the the wall thickness

don't think he could find a die to fit ?

 

[Screwdriver]

No, you'd have to make one which paradoxically is made easier if the two thin sides are constrained by the box section itself.

Like this:

I'd probably use a bolt into a threaded hole (since the die has to slide into a box section) and maybe use a roller bearing under the head. The sharp corners of the punch should grip the section to be cut out or you could use a keyed stud etc.

 

[knighty]

bolt is a good idea, I guess it could be done backwards, instead of pushing the punch down, pull it up ? that way you can have more support outside the box than inside ?

I'd worry the sides would deform pushing down, at least pulling up the top piece can support above (and to the side?) of the sides

 

[Screwdriver]

bolt is a good idea, I guess it could be done backwards, instead of pushing the punch down, pull it up ? that way you can have more support outside the box than inside ?

I'd worry the sides would deform pushing down, at least pulling up the top piece can support above (and to the side?) of the sides

Yes you could but if you think about it, the sides don't need support. The die fits the box section and the box section itself resists deformation as well as the two longer sides of the die.

With the punch inside the box section, alignment is also a bit more tricky. You could use the sides of the component as a guide. Depends how accurate the cut needs to be. Flush with the thickness of the section would make things a lot easier.

 

[SpeedyJD]

Whether pulling the punch inside out or pushing the punch into the box with the die on the inside 1) I can't find a 30mm punch 2) What piece of equipment do I need to excert that amount of pressure to cut through 1/8" thick aluminium? Thanks.

 

[Screwdriver]

M10 bolt with 1.25 would do it. Four small holes drilled at the corners would help tremendously but aluminium shears quite easily.

 

[SpeedyJD]

A right shame I wouldn't be able to fit this punch inside the box and punch it inside out. I think the punch is just too wide.
http://m.ebay.co.uk/itm/Hole-Punch-...-32-x-32-mm-D-SET-32-/321739905294?nav=SEARCH

 

[Screwdriver]

Just wondering out loud if you might even get away without having to use a die. Just wedge a block of urethane into the box section and punch through with a flypress.

 

[Kent]

4 holes, jig saw is OK but the filing after is taking a while. Just wondered if there was a quicker way. I'll have a look at the die and press. Thanks so far.

You are using the wrong file I recon. You don't want the regular diamond cut as they clog. Rather a long row of teeth like a mill file

 

[bigegg]

If you could get away with slightly rounded corners (or be prepared to file), I'd use a woodworking router and a template.