Router and aluminium

[Beeezer]

has anyone used a hand held router to trim it round a wooden frame?

Thinking of making some cupboards for a camper van I'm doing.

Had a thought of making the wooden carcasses up then covering in 1mm aly and trimming the edges with a router.

Your thoughts??

Cheers.

 

[Seadog]

It can be done. I used a router to bevel the edges on 3 x 2 metre strips of 3mm 6061. Carbide cutter essential, and take a lot of care.

 

[bigegg]

eye protection!
1mm aluminium will cut fine with a TCT bit

If you have a variable speed router, reduce the speed - I've done it at full speed though.

 

[Seadog]

eye protection!
1mm aluminium will cut fine with a TCT bit

Good point BE

 

[Beeezer]

Cheers, I shall have a play at the weekend.

 

[Parm]

Safety Specs are a must

 

[Beeezer]

I totally agree.

Will be interesting to see if my idea works, will keep the weight down in me camper van!

 

[FoxZulu]

I've used my little 1/4" Makita laminate cutter (mini router) to very good effect on ally. Just make sure that the work piece is well clamped down.

 

[thinfourth]

and wear long sleeves

 

[Jim Davey]

Spray the cutter regularly and the edge of the material with WD40 or similar. Ally has a tendency to stick to cutters causing rough cuts or damage to the router bit.
Tallow or candle wax will do in a pinch.

 

[Seadog]

Or white spirit, which may be a better option if you have wood underneath.

 

[julianf]

Spray the cutter regularly and the edge of the material with WD40 or similar. Ally has a tendency to stick to cutters causing rough cuts or damage to the router bit.
Tallow or candle wax will do in a pinch.

Exactly this.

Too little lubrication, and the alloy will "smear" into the cutter flutes, and it all goes wrong from there.

My cnc machine is chewing its way though a 2.0mm sheet as i type this. Its doing so with a single flute end mill, going down 0.5mm at a time, and kerosene lubrication.

 

[julianf]

ps. the variable speed potentiometer on my spindle broke about a year ago, so its been stuck on full rpm since then

shallow cuts, at high rpm, with plenty of lubrication, and you will get a clean finish.
no lube and high rpm will smear the job, dull the cutter, etc.etc. but, set up nicely, its not an issue.

 

[Parm]

Exactly this.

Too little lubrication, and the alloy will "smear" into the cutter flutes, and it all goes wrong from there.

My cnc machine is chewing its way though a 2.0mm sheet as i type this. Its doing so with a single flute end mill, going down 0.5mm at a time, and kerosene lubrication.

Kerosine Lubrication ?

Your brave !

 

[julianf]

Its not uncommon for aluminium.

Maybe i should try tossing a match at it and seeing if it ignites. Im not sure how much more volatile it is than diesel - you can throw a match in a puddle of diesel and it will just go out. I know kerosene is a little more keen, but i suspect not that much more.

I used to use water soluable oil, but it requires more time for removal, and it sticks the swarf to everything.

 

[Seadog]

Kerosine Lubrication

Another one that we used to use when at school. That's why WD40 works, I believe it has kerosene in it.

 

[Parm]

Another one that we used to use when at school. That's why WD40 works, I believe it has kerosene in it.

Didn't know that

 

[WorkshopChris]

Kerosine Lubrication ?

Your brave !

I think that every time i use the spark eroder, tank full of paraffin parts submerged and the spark burning away. It just looks wrong.
Paraffin / kerosine is a good old school aluminum lubricant we still use it for drilling and tapping, but good paraffin is getting very hard to source now.
Got the last lot on ebay as it was the cheapest i could find 4x4 ltr for £30.00.

To the OP the hardest part is keeping the bearing on a guided cutter clean, you can get special cutters with a smooth portion the same diameter as the cutting edge, but unless you are doing lots its not worth the expense.

 

[Beeezer]

Or white spirit, which may be a better option if you have wood underneath.

I like the idea of that, yes there is wood underneath.

 

[Beeezer]

Had a little play today with a cheapy router cutter with no lube, just experimenting.

Think this is the way I'm going.

This was with a 45 deg cutter, going to see if I can find a carbide one as suggested.