Results 1 to 9 of 9
  1. #1
    500+ This must be a daytime job



    Join Date
    Jan 2007
    Location
    NEW ZEALAND
    Posts
    908
    Contribute If you enjoy reading the
    content here, click the below
    image to support MyCockpit site.
    Click Here To Contribute To Our Site

    Routing Aluminium with a Trimmer router

    Hi guys,
    Have the following small desktop router. The spindle is a Bosch Colt
    router with a speed range of 16000 to 35000.
    Wanting to cut Aluminum with it, seen others do it but need to know
    Feed rate and Spindle speed. Any calculator I use when using a 3mm
    bit say my spindle speed min is to high.
    I have been cutting 2mm aluminum but the bit seems to get to hot
    as seen with it discoloring. Have tried different feed rates. It seems to cut alright but tip life wont be great.
    I had been using a HSS end mill but even if I plug in a Carbide bit these
    calculators say my spindle speed is to high for the bit size.
    Any one using a setup similar to my one and would like to comment,
    It would be much appreciated.
    Thanks
    Les

  2. #2
    300+ Forum Addict Shawn's Avatar
    Join Date
    Mar 2008
    Location
    Kamloops, British Columbia
    Posts
    425
    Contribute If you enjoy reading the
    content here, click the below
    image to support MyCockpit site.
    Click Here To Contribute To Our Site

    Re: Routing Aluminium with a Trimmer router

    Chip load on the tooth is what really matters in the end. The higher the spindle speed the faster the feed rate required to achieve a proper chip load per tooth. I use a single flute endmill for aluminium and plastic to help increase the chip load but I don't spin the bit at the same speed as you either. I calculated 25ipm feed rate for a 3mm two flute endmill in 6061 aluminum? that's pretty fast for a small router table. I use a continuous blast of air to cool the bit and remove chips and that really helps a lot on my setup, better than coolant for aluminum and plastic. The calculators don't take into account how ridgid your setup is, how much backlash etc, its a good place to start but sometimes we just have to take what our tools can give us and live with it.

    Shawn

  3. #3
    500+ This must be a daytime job



    Join Date
    Jan 2007
    Location
    NEW ZEALAND
    Posts
    908
    Contribute If you enjoy reading the
    content here, click the below
    image to support MyCockpit site.
    Click Here To Contribute To Our Site

    Re: Routing Aluminium with a Trimmer router

    thanks Shawn,
    What speed does you operate your spindle at?.
    Les

  4. #4
    300+ Forum Addict Shawn's Avatar
    Join Date
    Mar 2008
    Location
    Kamloops, British Columbia
    Posts
    425
    Contribute If you enjoy reading the
    content here, click the below
    image to support MyCockpit site.
    Click Here To Contribute To Our Site

    Re: Routing Aluminium with a Trimmer router

    I have a small milling machine that I converted to CNC so the spindle only runs 4000rpm max but I have added a small die grinder attachment that I use for engraving and it runs between 20,000 and 48,000rpm so I am on the far end of each spectrum.

    Shawn

  5. #5
    500+ This must be a daytime job



    Join Date
    Jan 2007
    Location
    NEW ZEALAND
    Posts
    908
    Contribute If you enjoy reading the
    content here, click the below
    image to support MyCockpit site.
    Click Here To Contribute To Our Site

    Re: Routing Aluminium with a Trimmer router

    Thanks Shawn,
    I have controller I bought a few years back that will allow a Router to operate down to
    5000 rpm and still have good torque. So I must hook this into my system, it should help
    me a lot.
    Regards
    Les

  6. #6
    300+ Forum Addict Shawn's Avatar
    Join Date
    Mar 2008
    Location
    Kamloops, British Columbia
    Posts
    425
    Contribute If you enjoy reading the
    content here, click the below
    image to support MyCockpit site.
    Click Here To Contribute To Our Site

    Re: Routing Aluminium with a Trimmer router

    Getting the RPM down and going to a single tooth cutter will make a big difference. When you hit the sweet spot on the speed and feed rate aluminium cuts like butter.

  7. #7
    500+ This must be a daytime job



    Join Date
    Jan 2007
    Location
    NEW ZEALAND
    Posts
    908
    Contribute If you enjoy reading the
    content here, click the below
    image to support MyCockpit site.
    Click Here To Contribute To Our Site

    Re: Routing Aluminium with a Trimmer router

    Thanks,
    I was wondering about using a single tooth cutter. After what you have said I must try one.
    Les

  8. #8
    MyCockpit Support Staff


    Westozy's Avatar
    Join Date
    Nov 2005
    Location
    Perth, Western Australia
    Posts
    1,415
    Contribute If you enjoy reading the
    content here, click the below
    image to support MyCockpit site.
    Click Here To Contribute To Our Site

    Re: Routing Aluminium with a Trimmer router

    I use quite a lot of 3mm aluminium for my components and I find the best results are achieved by "economical" cuts. I use a single fluted 3mm end mill and generally choose the speed by ear. I have a Kress spindle in my CNC which can do 6000 to about 30000RPM. I would cut aluminium at 200mm per minute with a depth of only 1mm so therefore 3 passes and I dial in a speed from mid range down to where it sounds like the spindle isn't labouring. This stops the tool from overheating and I find the best finish on the edge is achieved by "climb" cutting. It is slower than machining plastics but this method always gives a good result and the tool bits last for ages. A spray oil such as CRC or WD40 is an excellent lube/coolant although a bit messier!
    Cheers Gwyn

    737NG using Prosim737, Immersive Calibration Pro, Aerosim Solutions motorized TQ & cockpit hardware, CP Flight MCP & FDS SYS1X, SYS2X & SYS4X, FDS PRO FMCs, AFDS units & Glarewings, Matrix Orbital ELEC display, Pokeys Landing & Cruise alt display, Buttkicker Gamers, 3 x BenqMW811ST projectors with a Matrox Th2Go
    http://www.aerosimsolutions.com.au
    Supporter of MyCockpit.org, please join me in donating!!!

  9. #9
    500+ This must be a daytime job



    Join Date
    Jan 2007
    Location
    NEW ZEALAND
    Posts
    908
    Contribute If you enjoy reading the
    content here, click the below
    image to support MyCockpit site.
    Click Here To Contribute To Our Site

    Re: Routing Aluminium with a Trimmer router

    Thanks Gwyn,
    Are your cutters Carbide?.
    Les