I got this device once that came with a stainless steel sink from ikea. It was for punching faucet holes in the sink. It was like a punch where you drill a pilot hole in the metal and then pull one half into the half on the other side by tightening down on a bolt. I'm not explaning it well, I know, but it made a nice clean hole. I was wondering if that device came in different sizes. I haven't seen one since.
What's the best way to cut up to 3" holes in 1/8 aluminum and also to cut curves in 1/8" aluminum sheet? I was going to try a router on a medium speed. Do you think that would work?
I have only used hole saws and cut off disks in an angle grinder for doing that. Depending on how big of a sheet of aluminum you are using, a scroll saw with a metal blade might do the trick.
Hole saw on the holes, (Backed up with a piece of board, ) The curves can be cut on a bandsaw with around an 8-10TPI again backed up with a board. The regular bandsaw speed of 3000 FPM is fine for aluminum. If the chips start stickin to the blade spray it with WD-40 that works as a good lube on aluminum.
A router will work, again backed up with board, but get ready to get showered in HOT chips.
I use my table saw, cut off saw and router table for aluminum. I use the same blade as I do for wood, and have never damaged it. On my router table, I only use carbide bits, and turn the RPM down. Wear safety glasses and long sleeves.
For round or intricate holes, I use my cnc plasma table.
Hole saws always oversize the hole . If you need a tight fit its easier to drop it down a 1/8 th and finish it by hand . I have a few old reamers I keep around to stick in a die grinder to trim aluminum. It will stick like snot to anything else and you will spend more time trying to clean a bur then it would of taken to file it.
I got this device once that came with a stainless steel sink from ikea. It was for punching faucet holes in the sink. It was like a punch where you drill a pilot hole in the metal and then pull one half into the half on the other side by tightening down on a bolt. I'm not explaning it well, I know, but it made a nice clean hole. I was wondering if that device came in different sizes. I haven't seen one since.
aluminum being non ferrous will cut easily with wood style blades or saws, carbide tipped the best and cut slow to prevent melting the aluminum and plugging up the blade. abrasives will work but tend to simply melt the aluminum.
If I'm using a hole saw on something important I like to to pre-drill the centering hole. If not, as the drill bit of the hole saw goes through the metal it can suck the hole saw down too quick, causing it to grab and break off the drill bit. Then of course the saw will skate across the surface and gouge everything.
For straights and curves ditto on the table/band saws with a lube. For cutting different dia. circles I use an adjustable circle cutter chucked into my radial drill press set to a low RPM.
Here's a little tip I learned about a long time ago. When filing or using a burr on aluminum, run the file or the burr on some handsoap to prevent clogging. Nothing stops clogging but soap sures slows it down!
That's them! There's a lot on ebay. Do you think they would work well on aluminum?
Yes, they work just fine. I have the smaller 'bolt drawn' sizes up 1 1/8th and a hydraulic powered one to 3 inch. Either will go through 1/8 inch or less aluminum material with little effort. Same with the hydraulic unit in 3/16th aluminum checker plate. Haven't tried anything heavier though. I've used bee's wax that comes in a sleeve (meant for metal cutting saw blades) on the cutting edge of the die, leaves a cleaner shear/cut and nicer end result. Electricians use hole punches a fair amount for conduit in junction boxes etc. That's where you'll find the "Greenlee" brand (who is owned by Textron) mentioned earlier. Google any of those names and you can get info on them. Home Depot used to carry Greenlee brand tools at one time. Don't know if they still do not, other big box stores might carry a version as well. They can be spendy though if your looking for whole sets. Depot sold separate sizes. Don't know if Princess Auto still carries them or not, you would have to check it out.
That's them! There's a lot on ebay. Do you think they would work well on aluminum?
Yes, they work just fine. I have the smaller 'bolt drawn' sizes up 1 1/8th and a hydraulic powered one to 3 inch. Either will go through 1/8 inch or less aluminum material with little effort. Same with the hydraulic unit in 3/16th aluminum checker plate. Haven't tried anything heavier though. I've used bee's wax that comes in a sleeve (meant for metal cutting saw blades) on the cutting edge of the die, leaves a cleaner shear/cut and nicer end result. Electricians use hole punches a fair amount for conduit in junction boxes etc. That's where you'll find the "Greenlee" brand (who is owned by Textron) mentioned earlier. Google any of those names and you can get info on them. Home Depot used to carry Greenlee brand tools at one time. Don't know if they still do not, other big box stores might carry a version as well. They can be spendy though if your looking for whole sets. Depot sold separate sizes. Don't know if Princess Auto still carries them or not, you would have to check it out.
Thanks guys! Got all the info I need. I'm going to buy a set of Greenlees to go with my set of dimple dies. Now I just need a shop press.
When I used to work with aluminum I used a wax lube that comes in a tube just like grease. Band saw , table saw radial arm saw just start up the blade, touch the wax stick to it and that works better than wd 40. Not sure where my previous employer got it from but it works real good . Evan works good for hole saws too. I used to make aluminum dump trailers. Lots of holes for lights and small pieces to weld. Check mechanical supply shops for the wax stick. Remember when using power tools that when they get gummed up they dig right in. So hang on!
