Working with Aluminuim

Aluminum materials gone gummy if you don't cut it aggressively.
You cannot use grinder on them because they are too ductile for grinding abrasives.

Best way to cut them when using power saws is to use candle/bees wax on the saw as lubricant before you cut and during the cut if the cut takes more than 30 seconds all up.

On files, simple, just file some chalk just before you file aluminum. The chalk will work as release of the filings from the teeth. Just remember to re chalk every so often. You can use common blackboard chalk but builders chalks are better.

You can use tungsten woodwork router on aluminum but make sure you do not generate too high heat that it break the brazing of the tungsten teeth. Be very careful when using tools not designed for what they are made for, what seems easy will became very dangerous unless you take very good care of what you are doing.

Have fun and be safe.

Oh yes: If you have any more problems with the Keil tools, be sure to post them here.

Aluminum materials gone gummy if you don't cut it aggressively.
You cannot use grinder on them because they are too ductile for grinding abrasives.

Best way to cut them when using power saws is to use candle/bees wax on the saw as lubricant before you cut and during the cut if the cut takes more than 30 seconds all up.

On files, simple, just file some chalk just before you file aluminum. The chalk will work as release of the filings from the teeth. Just remember to re chalk every so often. You can use common blackboard chalk but builders chalks are better.

You can use tungsten woodwork router on aluminum but make sure you do not generate too high heat that it break the brazing of the tungsten teeth. Be very careful when using tools not designed for what they are made for, what seems easy will became very dangerous unless you take very good care of what you are doing.

Have fun and be safe.

Oh yes: If you have any more problems with the Keil tools, be sure to post them here.

Alcohol (ethanol or methanol) works well on the tools, to stop the aluminium from sticking to the drills etc. It will also work as coolant.

Forget Methanol, it is toxic (much more than ethanol ;-).

"Forget Methanol, it is toxic (much more than ethanol ;-)."

Of course it is. I made a recommendation for aluminium work, not for the friday party ;)

The easiest way to get alkohol is to buy fuel for spirit stoves.

I'm sure that this information must be in the Bible everyone keeps talking about around here.

There are special files for aluminum that clog less. They will be stamped with the word 'ALUMINUM'. Put a very light (not dripping) coating of TapMagic Aluminum (http://www.tapmagic.com) on the file to help prevent loading. It is normal and expected to use a file brush every couple of minutes to clear the file teeth. One side of the brush has stiff hardened wire bristles and the other is like a stiff kitchen scrub brush.

Remember to hold the file correctly and to lift the file during the return, non-cutting stroke.

See the Wikipedia article: en.wikipedia.org/.../File_(tool)

Oh, almost forgot. You are probably not using 'aluminum' but rather an alloy. Some alloys are better suited to certain machining operations than other. 6061-T6 is a particularly well known, often used alloy for high strength. Know your materials.

I'm sure that this information must be in the Bible everyone keeps talking about around here.

there is ALU minimum :)

Erik

In no particular order:

http://www.keil.com/forum/docs/thread12851.asp

http://www.keil.com/forum/docs/thread12832.asp