hand routing aluminum .040

[nashvillesigns]

is really new to me. i tried it last friday. grabbed a bit, made a mold, layed down some .040 aluminum sheets to cut it and..
1. the bit SUCKED.
2. about two inches in, the metal started to MELT.
3. doesn't matter what speed the router goes, same result as number two.

i am using a 2 horse power varable speed router.

i had twelve signs to cut the tops off of like my mold was made. basically three half circles..
i ended up using a jig saw with a metal blade. Boy was i sore Saturday morning...

recommendations for next time?

 

[ggsigns]

First your material was not the correct alloy for machining. The more expensive materials cut better. You'll need to keep the bit and material cool while cutting to prevent the melting you experienced.

If you can't get the better alloy, spray the bit with WD-40 or similar material, cut 2-3 inches, spray again, repeat, repeat, repeat. Or have a helper spray the coolant while you work the router. It's messy but you will get much cleaner cuts.

 

[Mosh]

Not going to work, wrong bit, wrong router. In the future if all you have is a "home depot" type router, use max-metal or poly metal instead of .040, it routes easily.

 

[artbot]

i'm guessing you had 3003 vs 5052 (which cuts easily). i've been hand routing aluminum for decades and it's just a matter of set up. 5052, good quality straight cut is a great common bit for this purpose. some might suggest single flute upcuts and such. a template guide/sleeve works well for basic low detail cuts. use a sheet of XPS under the aluminum to avoid drag and heat build up. any router will do. .040 is very thin. you'll get used to the sound you are shooting for. listen for a bright whistling sound. if you go too slow, you'll have heat build up, if you go to fast, you'll bog down the bit.

 

[Techman]

I cut AU all the time with a router.
Yes it will build up on the cutter. That is why real machinists use a cutting fluid such as tap magic for AU to help out with the task.

The idea is to keep the chips moving away from the cutter bit.

 

[J Hill Designs]

you may also try cutting the opposite direction of travel