cutting aluminum and steel in a totally inexperienced newcomer's limited shop

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mtgrizzly52

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Ok, This will be my first dumb question for the forum to laugh at, and hopefully will help me out with.

I'm about to embark on my first metal project with my micro-mill (LMS) and will hopefully end up as a carriage stop for my HF mini-lathe. I have a block of aluminum 6061 that is 1 1/4"x1 1/2" and about 7" long. The carriage stop is 1 1/2" x 1" with a slot cut out of it to fit over the back way of the lathe. Here is a link to what it looks like. http://littlemachineshop.com/Projects/CarriageStop.php

I'm assuming the slot is milled on the milling machine. My question is what can I use to cut the aluminum block down to the correct overall dimensions. I have an old chop saw and a metal cutting blade (never used) that looks like fiber, not a normal looking saw blade. I have a 12" bandsaw, but I really don't want to use that if possible. I guess I could use a hacksaw, but I want to get this project done in the next century, plus hand saws and I don't like each other. I also have a brand new tablesaw, that I really don't want to cut metal with if at all possible.

Please help me figure this out, and if you have any better suggestions for how to do this project (put it in terms a simpleton (me)) can understand. Also if you have any suggestions for a better type of carriage stop I could make, I'd love to hear about it please.

Thanks All for any help or suggestions you can give. Next I'll be working on building some lathe dogs....that really ought to be interesting!

Rick (mtgrizzly52)
 
I would cut the 7 in. dim. down with the hacksaw, and mill the rest. If the fiber saw you are referring to is a chop saw with an abrasive blade, it won't cut aluminum. Think of it as a really thin grinder. The blade will load up. Always remember, in a shop full of cnc machines, and manual lathes and mills, the fastest and most efficient way to remove materal is still a saw.
 
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Don't use the fiber blade on aluminum, it will load up, bind, and in the worst case, self destruct. Hacksaws aren't too bad, I cut all my stock with one when I first started, before I got my little 4x6 bandsaw. Going through a 2x2 piece of aluminum isn't fun, but doable. A spritz of WD-40 every once in a while helps. Using the coarsest blade you can find also helps.

Another thing you might try, if you have it, is a Sawzall with a longer, bi-metal blade.

If that 12" bandsaw is a wood bandsaw.. I don't think I would cut aluminum on it, though it would probably work.

Whatever you decide, make sure you cut the stock a little oversize so that you can square it up.
 
A sharp bi-metal 18 tooth hacksaw blade with some stick wax lube will walk through your stock in very short order. I used to cut all my stock that way, including 1-1/4" square 6061-T6 in eight strokes. At some point, consider a metal cutting bandsaw but you don't need one to start.
 
Please don't try the table saw, even if you have a carbide blade. Far too dangerous. It turns way too fast for that material. I'm with most of the others, hacksaw with a good blade is your best bet out of your current choices. Good luck with your project.

Doug
 
Face off one end of your stock in the mill by having it stick out from the vise at least the amount of the desired part. Remember not to do a hill climb cut. Next, move the bit over the correct desired length of the part (including the width of the bit) and slice through it. Bingo, you've faced one end and cut the part to length in 2 operations. No sawing needed.
 
For those worried about cutting Al. on a wood bandsaw, don't worry. I have an old Craftsman wood bandsaw and cut Al. on it with no problem using wood cutting blades. It cuts Al. about like it cuts oak.
Bobby
 
I've cut hard steel 1" thick 2' x 3' with 10" metal cutoff wheels on my Delta tablesaw. I wear a full face shield, gloves and ear protection. I take many passes on both sides, raising the wheel higher slightly with each pass. The abrasive wheels at Lowes are less than 4 dollars.

Aluminum is easy to cut thru, but I don't use abrasive wheels for that. A hacksaw works fine. I've got a cheap bandsaw that also works for alum.

I'm sure someone will chime in to tell me I'm doing wrong cutting the steel :-)

DaveV
 
Personally, I would think of it as an advantage to leave it in one piece while machining it. Gives you something to hold on to in the vise. Once your milling is complete, put a small endmill in and cut it partially and then finish up with a hacksaw.

I do use my woodworking bandsaw at times and also a little portable HF bandsaw. It's not too hard to clean off the bandsaw after aluminum as long as you don't go slow and let the aluminum gall up on the blade. A little WD40 does wonders.
 
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