Hole Cutting

[johnny max]

Hi All
Need to cut or drill 52mm holes in 3mm aluminium sections.
Have made one of those Weldon adaptors that takes a broach bit.
What lubrication can I use if any at all and also these will be welded.
Tubes will be passing through these holes.
Any info appriaciated
Johnny

 

[dan.taylor.1]

I use soluble oil for broaches, they need to be kept cool and don't let them just sit on the material whilst spinning with no pressure as this kills them, though not sure how they cut in ally and I doubt it's hard enough to blunt a broach.

Can you not get a holesaw in that size? With a decent pillar drill they'd be just as quick, and cheaper I'd think.

Dan

 

[johnny max]

The guy was using a holesaw but he said it was to time consuming.
I.m planning to do it on pillar drill
Can I use the water solable on ally and axpect to weld ok ??
Johnny

 

[dan.taylor.1]

Any cutting fluid is going to need to be cleaned off for welding so i don't think it makes a difference what you use in that respect.

Dan

 

[SBK]

You can get bi metal hole saws that size.
Ive used them to cut stainless tube.
A arbour and 22mm cutter are less than a tenner.

 

[mike 109444]

Paraffin use to be the cutting oil of choice many years ago. I have used white spirit before now

 

[Mr shiney]

I cut holes that size with the plasma in about 5 seconds. Might be a thought?

 

[johnny max]

Well I cut 65 holes in 2hrs
Worked very well

 

[hareng]

I do it almost daily usually up to 5/8" deep irregular shape with no centre drill and coolant. Aluminium gets hot quick and holds the heat.

Did the holes come out central?
Or cut well oversize.

 

[Hitch]

Broaches work sweet on ally, holesaws are okay, but slower, and not quite as neat.

 

[awemawson]

Well I cut a 105 mm hole through 3 mm steel plate today with no issues using a hole saw and soluble cutting fluid

 

[johnny max]

I do it almost daily usually up to 5/8" deep irregular shape with no centre drill and coolant. Aluminium gets hot quick and holds the heat.

Did the holes come out central?
Or cut well oversize.

I didn.t use coolant because by the time I set up for next hole. The broach cut each hole perfect and was quick enuf. I had to drill 3mm hole to help centre each because of shape of sections.

 

[MattF]

Paraffin use to be the cutting oil of choice many years ago.

I still use paraffin.

 

[hareng]

Good to see using a decent hole saw bi metal variable pitch Starret, they work well.
Coolant would have aided cutter life in turn less heat build up, though a dispensable item.

Went of those types some years back, pain to change cutter over quickly and sods law the cross pin would only go in where theres play.
Still have some runout using the Bosch system but quick release and cutters last a it longer.

 

[awemawson]

The spray bottle sitting on the plate is soluble oil nicked from my CNC milling m/c