17/32” radius channel

D

dpb

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I would like to cut a round bottom channel in 6061 aluminum, about .075” deep, with a radius of 17/32”. I can’t find a tool to do this, I’ve also looked at router bits. I know I could do short sections, using a boring head, but I’d really like to find a cutter, or method that would allow me to cut a channel 10-12” long, relatively easily. I have a knee mill, with dividing head and rotary table, boring heads, and a lathe.
Any ideas?
 
Use a regular appropriate sized end mill and tilt your head on your mill . You'll cut a radius . May not be perfect but maybe it doesn't have to be . Regrind a ball mill to size needed .
 
This 17/32" ball end mill would do the trick, no?
www.ebay.com

17/32" Ball End 2 Flute Melin Cobalt End Mill Center Cutting 733438103820 | eBay

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Not cheap for a one-off feature. But depends on what you need it for.

There could be cheaper sources, this just popped up first.

EDIT: This would give you a 17/32 diameter, not radius....
 
I was editing my post as you replied, @mmcmdl! You beat me to it.
 
It will be mated to the outside of a 1-1/16” tube, so the radius needs to be very close.
 
What if instead of a radius, you milled in a V-groove?

Do you need full bearing on the tube? A V-groove would give you two lines of bearing for your tube.
 
I would prefer full bearing, for aesthetic reasons. A v-groove would absolutely work, strength-wise.
 
I would grind an HSS D-bit. Basically, you make the shape out of HSS (or probably just some sort of steel, since you're only cutting aluminum), so a 1-1/16" ball at the end of a shaft. You'd use some sort of ball-turning jig on your lathe.

Then, grind it in half! Cut a small relief cut, then what is left is a single-flute endmill.
 
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