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Which router bit

M

mike.T

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Name
Mike Tait
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North Wales uk
I hope this is ok to post. I need advice on router bits.
Firstly this is not for wood but ACM aluminium composite panel 3mm thick.
I will need to router to a template, I intend cutting close to the edge then router the curve from a 10mm template.
Am I right in saying that the bit will have a bearing attached, if so could someone tell me the correct name please and the thickness of the cutter do i use 6mm or 3mm
I have a router makita handheld brushless 1/4, so assuming that would be fine. I believe i need a solid carbide flute router bit.
Any other advice greatly appreciated
Thanks
Mike .
 
Having had a think, if the ACM is a laminate of two thin aluminium sheets sandwiching some sort of plastic and if you are only doing this is a one off, I would think a good quality tungsten carbide tipped bearing guided template cutter could do the job. I would suggest a 1/4" cutter and a slow speed to allow the chips to evacuate and not to melt the plastic layer.

I also would highly recommend eye protection as well as practising on a waste piece first and as you say cut as much waste away first.

If this is not a one off, industry bearing guided aluminium cutters are expensive and it may be cost effective for you to research a local CNC machining service.

I am not an expert. I am just applying my HH router and CNC router experience.
 
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I used an 8mm diameter 4-flute TiAlN (titanium-aluminum-nitride) coated end mill in my Festool OF1010 router and guide bushing to cut keyholes in aluminum extrusion for my workbench project. The solid aluminum was thicker than your composite panel and I didn't have any problem with the end mill or the router.

I made the template out of scrap piece of 12mm plywood. The mirror image guide allowed me to mill two pieces of extrusion end to end with one setup.

Routing-Template-6.jpg

Routing-Template-5.jpg

Routing-Template-3.jpg
 
Nice job, that looks like T slot aluminium extrusion, Thats another job Im looking at building a roof rack, but struggling to get a definite answers to which profile I need. Thinking of 30/60.
 
Malc2098 said:
Having had a think, if the ACM is a laminate of two thin aluminium sheets sandwiching some sort of plastic and if you are only doing this is a one off, I would think a good quality tungsten carbide tipped bearing guided template cutter could do the job. I would suggest a 1/4" cutter and a slow speed to allow the chips to evaluate and not to melt the plastic layer.

I also would highly recommend eye protection as well as practising on a waste piece first and as you say cut as much waste away first.

If this is not a one off, industry bearing guided aluminium cutters are expensive and it may be cost effective for you to research a local CNC machining service.

I am not an expert. I am just applying my HH router and CNC router experience.
Click to expand...
Yes its a one off, Im building a square drop similar size to teardrop but a different shape. This is where i am up to.
 

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mike.T said:
Nice job, that looks like T slot aluminium extrusion, Thats another job Im looking at building a roof rack, but struggling to get a definite answers to which profile I need. Thinking of 30/60.
Click to expand...
I am happy to share what I know and have learned. If it helps, here is the build thread for my 2x1 meter MFT-style workbench on another forum:

www.ukworkshop.co.uk

MFT-Style Workbench

1. Introduction One of the items missing from my workshop is a large flat work surface that can be used for assembly and fabrication. I have a wooden Sjöbergs workbench, but want to reserve it for hand tool use. It's location makes it of limited use since it is against the wall and I can't...
www.ukworkshop.co.uk www.ukworkshop.co.uk

I used 40x40mm and 80x40mm extruded aluminum for the chassis, 19mm Valchromat for the top, and plywood for the dividers, drawers, and catch tray. I also used a length of 60x30mm extruded aluminum for the fence.

If I was making this again, I would keep the overall size as is and would make the side trays just deep enough for the Systainer boxes. I would build storage shelves in the center section for the guide rails and fence instead of using the catch tray.
 
I have done a 1/4” round over in one pass on 10mm aluminium bar with a cheap 1/4” cutter.
It was easy to do.
A solid carbide slot drill would breeze through the job

Pete
 
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