Friday, September 12, 2014

FridayCutFacts: How to Use a Router to Cut Aluminum for Sign Letter Fabrication.

If you are looking to prevail in the sign industry where flexibility and versatility are necessary for a business to succeed, then adding a reliable CNC router to your workflow is a no-brainer.

Whether you are working with wood, foam, or acrylic a CNC router can help generate the superior products that customers envision. But one question we are frequently asked by manufacturers is "Can your routers cut aluminum as well?" Our answer is always a resounding, "Yes! As long as you do it correctly."

There are a few things know about cutting aluminum on a router before you begin. First, like all materials, there is a "Sweet Spot" for the best feeds and speeds. When cutting aluminum, the "Sweet Spot" is much smaller, and the chances for breaking a bit and outputting a poor surface finish are increased. Secondly, aluminum heats up and becomes sticky when cutting, so if you venture outside of the "Sweet Spot" aluminum deposits will begin to weld themselves to your tooling or your cut piece.

To help you visualize the "Sweet Spot" for speeds and feeds of cutting aluminum, take a look at the chart below.

Here is a breakdown of the different zones in the graph.

High Chipload Feed: When your feedrate is too fast for a given spindle RPM, you're chances of breaking the bit are almost certain.
MRR: Running the spindle as fast as you can without burning the bit and feeding as fast as you can without breaking the bit is the "Sweet Spot" for Maximum Removal Rates.
Too Fast: Too much spindle speed will generate excess heat which softens the tool and dulls it faster. 
Best Tool Life: Slowing down the spindle a bit and feeding at slightly less than appropriate for maximum MRR gives the best tool life. 
Surface Finish: Reducing your feedrates while keeping the spindle speed up lightens the chipload and leads to a nicer surface finish. There are limits, the biggest of which is that you'll eventually lighten the feedrate too much, your tools will start to rub, and tool life will go way down due to the excess heat generated by the rubbing.
Older Machines: So your spindle speed has come way down, and in addition, so has your feedrate. You're probably on an older machine where you can't run the kind of speeds you need to take advantage of carbide tooling. You may need to switch to HSS. 
Feeding Too Slow: Feeding too slow leads to rubbing instead of cutting, which can radically shorten your tool life and is to be avoided.

PUTTING IT TO THE TEST:

When cutting 6061 1/8 inch aluminum for sign letter fabrication we used a 63620 Stub Nose 1/4 inch Up-Cut Bit at 22,000 RPM and at speed of 100 in./min.
Multicam Cutting Aluminum

Multicam_Aluminum1

 HELPFUL TIP: Be sure to use a lubricating mist to cut down on the tendency for the chips to stick to the cutting edges. The optional mister on thisMultiCam 3000 router provides both an air blast and a coolant mist.
Multicam_Aluminum2

Notice how these chips aren't too flaky! They are exactly what you want to see when cutting aluminum. Its a good sign that your feeds and speeds are in the "Sweet Spot". At 22,000 RPMs, the chips produced were hot enough to transfer the heat to the chips instead of the finished piece or the tooling.

multicam_aluminum3

Here is our finished piece. As you can see cutting aluminum is entirely possible with a CNC router. It's just a matter of matching your machines capabilities to the "Sweet Spot" feeds and speeds of the material. 

multicam_cnc_aluminum4

VISIT MULTICAM.COM

47 comments:

  1. Fellas, would really appreciate you linking back to CNCCookbook where your sweet spot graphic originated: http://www.cnccookbook.com/CCCNCMillFeedsSpeedsBasics.htm

    ReplyDelete
  2. The article has really peaks my interest. I am going to bookmark your site and preserve checking for new information. Laser cutter

    ReplyDelete
  3. This is really my very first time here, great looking blog. I found a lot of interesting things inside your blog especially its discussion. From all the remarks in your articles, it appears like this is really a extremely popular website. Keep up the truly amazing work. Laser Cutter

    ReplyDelete
  4. Your blog provided us with valuable information to work with. Each & every tips of your post are awesome. vashikaran specialist

    ReplyDelete
  5. The particular suggest presents totally helped myself more complex my directive. My own loved one and also i need been the actual language troubadour for any as opposed to immediately, along with little help personalized via my convenes. Accredits to your account, My own loved one and also i upright ruminate regarding banquets close to that i is usually efficient at panel my pure talent. NEET Preparation in Mumbai

    ReplyDelete
  6. I all the time used to study article in news papers but now as I am a user of net thus from now I am using net for posts, thanks to web. Take a look at my homepage.. Haryana State Board of Technical Education (HSBTE)

    ReplyDelete
  7. Congratulation for the great post. Those who come to read your Information will find lots of helpful and informative tips.Palmdale homes for sale

    ReplyDelete
  8. This excellent website developed every little thing I did so to get which look nothing at all. The reason being that is certainly this kind of helpful write-up. I want to to a lot thanks due to this in depth comprehend with all the topic. BC marijuana dispensaries

    ReplyDelete
  9. I should say only that its awesome! The blog is informational and always produce amazing things. Black granite

    ReplyDelete
  10. We are really grateful for your blog post. You will find a lot of approaches after visiting your post! amazon bewertungen verbessern

    ReplyDelete
  11. With exercise bike like this, I can feel the respiratory system that is better than before exercise. Therefore I think there is no harm if we change the unhealthy lifestyle that we've run with a healthy lifestyle. CBD business Canada

    ReplyDelete
  12. You certainly fully understand what you're talking about, and I can truly get behind that. thank you for all the great content. how to start a cannabis business

    ReplyDelete
  13. You truly did more than visitors’ expectations. Thank you for rendering these helpful, trusted, edifying and in addition cool thoughts on the topic. pompano beach condos for rent

    ReplyDelete
  14. Your blog provided us with valuable information to work with. Each & every tips of your post are awesome. Thanks a lot for sharing. Keep blogging, אגזוזי ספורט

    ReplyDelete
  15. Your site is one of the beautiful place and I am delighted to find some more information about its natural beauty. Now I am much excited to visit it. fake ids

    ReplyDelete
  16. Your site is one of the beautiful place and I am delighted to find some more information about its natural beauty. Now I am much excited to visit it. Toyota 4runner Off Road Bumpers Online

    ReplyDelete
  17. You're in point of fact a just right webmaster. The website loading speed is amazing. It kind of feels that you're doing any distinctive trick. Moreover, The contents are masterpiece. you have done a fantastic activity on this subject! Hjælp til jobsøgning

    ReplyDelete
  18. Absolutely superb data! I’m on top of that a specialist on this issue i must say i are able to know your current. Full Mount Fish Replica

    ReplyDelete
  19. As i accurately planned to say thanks again. I am uncertain stuff When i could very well have done interior not enough these kind of progressive suggestions uncovered having people with this distinct market place. Lottery Results

    ReplyDelete
  20. As i large enjoy this distinct write-up. It’s hard to be able to these people effective through your weak every now and then, nonetheless I do think you’ve nailed which! might you mind upgrading your site with additional facts. Monogrammed Leather

    ReplyDelete
  21. As i undoubtedly enjoy your site and locate nearly all your own personal information being just what I am in search of. Chain Barrier

    ReplyDelete
  22. My own educators spot produced myself towards the increase amount portion bonuss pertaining to speed. My partner and i recognized in the cheap that they can would abrogate twinge myself. I would end up being facing in order to well known panelist that received the actual great associated with putting axe crown towards the protection. Nonetheless, synchronous the actual connections associated with precision, no need to agony. Engineering mumbai university

    ReplyDelete
  23. Hello,
    I will read your whole article, that is very nicely written and informative also. Thanks for sharing keep sharing these type of article.

    husband wife problem solution

    ReplyDelete
  24. Amazing insight you have on this, it's nice to find a website that details so much information about different artists. KBF Membership Plan

    ReplyDelete
  25. Simply wish to say your article is as astonishing. The clarity in your post is simply great and i could assume you are an expert on this subject. Well with your permission let me to grab your RSS feed to keep updated with forthcoming post. Thanks a million and please keep up the gratifying work. Paediatric Occupational Therapy Services

    ReplyDelete
  26. I care for such info a lot. I was seeking this particular info for a long time. Thank you and good luck. bamboo towels canada

    ReplyDelete
  27. A number of item anyone known as on the inside of write-up may very well be overly successful and also can be hugely successful. OK, I'll keep which usually since the main goal, best would like intended for offering the main points keep replacing, anticipating intended for additional facts. Regards.. hospital signage

    ReplyDelete
  28. Giving a compliment is the perfect way to show you care about someone,and it is a great way to express how much you appreciate another person. replacement windows nj

    ReplyDelete
  29. Your blogs and every separate material are so remarkable and lucrative it makes me come back most again. Paint correction

    ReplyDelete
  30. We need this informative article to do our task within university, and contains similar material together with your document. Love, amazing reveal. European License Plate Holder for Range Rover

    ReplyDelete
  31. I can see that you are an expert at your field! I am launching a website soon, and your information will be very useful for me. HUMAN BRAIDED WIGS

    ReplyDelete
  32. Great run! This is often the kind involving facts that needs to be spread around the world-wide-web. Analytics and Market Research

    ReplyDelete
  33. This is the great eye-catching post. I am almost content in relation to your own personal effective run. An individual collection honestly wonderful facts. شراء سيارات كلاسيكية امريكا

    ReplyDelete
  34. This short article you've got put involves massive information came into existence useful. Direct access barrister

    ReplyDelete
  35. We'd the same as to be able to have confidence in the past commenters! As i find this kind of website honestly ideal for the uni business. I'm hoping to add a lot more effective information later. تقويم الأسنان

    ReplyDelete
  36. Which is the new which the partner and also my spouse and i click on over and also I stumbled onto a lot of enjoyable issues inside your website specifically it really is talk, thanks. برنامج حسابات المغاسل

    ReplyDelete
  37. You need to understand can't, your own personal post moves to your nitty-gritty in the topic. Your current clarity in fact actually leaves us interested in a lot more. Just thus a person understand, i am going to promptly get the unique give sustain until now with your on the net website. Buy home décor items online london

    ReplyDelete
  38. This is some rare content. I repeat, this is some rare content. Well, me and my spouse have never seen such a rare kind of write-up content in our entire lives. And don't find that surprising because we are very good judges of articles. But, this content deserves more spots than other ones. That's why I called it 'rare'. pink sneakers australia

    ReplyDelete
  39. You completed certain reliable points there. I did a search on the subject and found nearly all persons will agree with your blog This post is very simple to read and appreciate without leaving any details out. Great work! baby girl outfits uk

    ReplyDelete
  40. This is such a great resource that you are providing and you give it away for free. I love seeing blog that understand the value of providing a quality resource for free. Used desktop Malaysia

    ReplyDelete

  41. Great Blog, there is so much reality written in this content and everything is something which is very hard to be argued. Top notch blog having excellent content. Aluminum CNC machining

    ReplyDelete
  42. I really love this article. It is filled with great enthusiasm, passion and great excitement. best online gambling

    ReplyDelete
  43. Eager for another great post. All the best for your article author! good luck! Bingo Games

    ReplyDelete
  44. I have enjoyed this great information so much. This was really very interesting and helpful to read. I cant wait to read more from this site. Low cost dental impalnts in bhopal

    ReplyDelete
  45. Hi that had been amazing to recognise to find out. Relation toward amazing write-up. Special almost all compared to of which.. The wholesale formula review

    ReplyDelete