Gotta be a better way

[nsfr1206]

I am machining my first aluminum flywheel. First one period. Was using carbide cutter but it seems like it's taking a long time. I tried the cutoff tool plunge cut suggested elsewhere but that is slow too plus it wants to chatter. And if I push the little 7x14 too much my flywheel develops a dish shape to it. How many hours should it take to take off 1/4 inch of aluminum?

 

[Brian Rupnow]

It shouldn't take more than 5 minutes, but carbide is not really great with aluminum. It will work, but not anywheres near as good as properly sharpened HSS.

 

[Bill Gruby]

Good call Brian. Carbide tooling is not the best for Aluminum. The heaviy cut will just start to gall and the finish suffers drastically. Change to HSS and you can push harder. 10-15 minutes max to remove 1/4 inch.

"Billy G"

 

[lensman57]

Hi,

I can cut off a 2" piece of aluminium on my little Taig lathe in about 5 minutes provided the the cut is as near to the spindle as possible. Aluminium loves to stick to the tip of the tool and make it very inefficient, I like the HSS T-bar that comes with the Taig's rear tool post, it really cuts well once ground and honed properly.

Try a decent and sharp HSS bit and don't let it extend any longer than necessary to make the cut or you will get chatter as the blade flexes under load, WD 40 works well with aluminium as a lubricant so does paraffine. If possible try and support the material by a live center in the tail stock to prevent the cut pressure pulling the stock out of the chuck's jaws, this is one of the reasons that you do not get a straight cut also lock the saddle in position to increase rigidity.

Good Luck.

A.G

 

[nsfr1206]

Thanks for the quick replies. I am facing so tailstock isn't being used. I'll need to try hss. And maybe some lubricant.

 

[rleete]

WD-40 works well to lubricate aluminum and give a decent finish.

 

[Brian Rupnow]

Supposedly Kerosene (coal oil) works great as a lubricant for aluminum, but I would think it would stink to high heaven. I buy a product in Canada at the Canadian Tire Store called "Multi Purpose Lube" that comes in an aerosol can and works well, has no odour, and is reasonably inexpensive.

 

[steamer]

Your both right ;D

The key ingredient in WD40 is Kerosene.....works great! albiet a bit expensive I suppose

Dave

 

[mu38&Bg#]

I use odorless lamp oil for aluminum, no smell. Just make sure what you buy is petroleum, not alcohol.

 

[Brian Rupnow]

Steamer--I was always lead to believe that the main ingredient of wd40 was a fish oil. The wd stands for water displacement, and the 40 represents the fourtieth compond tried and found to be ultimately succesfull.

 

[steamer]

http://en.wikipedia.org/wiki/WD-40

Active ingredients include Stodard Solvent...very similar to Kerosene.

Dave

 

[rake60]

Sharp cutting tools are needed for aluminum.
Carbide will work if it is a positive rake insert.

There is no better cutting fluid than kerosene for aluminum but WD40 comes close.

I used to face aluminum explosion covers for electric motors at work.
They were typically 2 feet X 3 feet. The face had to be perfectly flat and smooth so the
finish cuts were extremely light and surface speeds extremely high.

I'd spray the surface with kerosene from a spritz bottle ahead of the tool to keep the
cutting area coated.

Every now and then, the chip would get hot enough to cause a little yellow flame to flare
up at the tool when the kerosene reached it's flash point.
No big deal. Just blow it out like a birthday candle and keep cutting.

Rick

 

[Captain Jerry]

Turpentine works as good as kerosene and I think it smells better. The grade od aluminum makes a lot of difference too.

Jerry