I am thinking of accepting manufacturing aluminum parts.
I will need a compressor that can run for days without interruption. I will blow a mist of isopropanol alcohol in the part.
I am also not sure if the aluminum chards will not destroy my machine long term? I have found them in my ball nuts before while servicing, anyone out there cutting aluminum on a regular basis?
I have an aluminum wasteboard which helps reduce vibration a lot, so I get a decent cut quality although I have to go very slow due to having a hobby machine.
I machine aluminum almost exclusively on my modified Woodworker ATC setup. I usually run dry but with single flute and strong air blast for roughing and 3 flutes for finishing. I have experimented with IPA and it works well to cool the endmill and stock, but as mentioned the safety concerns should be respected. Even now with vastly more experience than 5 years ago I prefer to see the chips and cuts being formed, so typically do not use a vacuum but have designed and installed one I think works well. More often than not I use chip shields to contain (most) of the flying metal.
I live in a small semidetached home and my machine is in the basement, so I need to be cautious of sound, particulates, and odours. Another reason why I rarely use my IPA MQL system as there is not a good way to direct vent it. It is also the reason I went with a pair of California Air Tools compressors. The larger one (still small by shop standards) is used for all ATC - drawbar, air blast, and the high consumer air seal). The smaller is for all other - tool rack, dust shoe, tool setter - which can add up. I have run long jobs, which they are not really ideal for, but so far all has gone well.
I too mill aluminum dry, no air at all, and I use my ordinary craftsman 6 hp shop vac the trick is feeds and speeds, and the proper bit made for aluminum. I use both 1/2-and-1/4-inch bits. Spindle speed 15000 and feed at 10 IPM depth of cut just 15 thou. works perfectly for cutting my ultra -low profile clamps. machine is elite journeyman with stiffy and Masso controller. As you can see, I use my clamps to make my clamps:) Both on the table holding the fixture and, in the fixture, holding the work.
A similar discussion is happening on a ‘Projects’ thread. I thought you might find crashaffinty’s post about milling his material while it’s submerged interesting.
I don’t have any experience milling aluminum, but I’m enjoying all the conversations and different ideas around the subject.
I have to agree regarding looking for a different solution, unless you have exceptional ventilation. My first career was in commercial print and ‘back in the day’ we used IPA to (believe it or not) ‘harden’ the water that we used to wet the printing plates. IIRC the higher the percentage of IPA in the water the ‘wetter’ the plates ran, and was adjusted on a job by job basis. I can say without a doubt, working in a small shop with no OSHA oversight that it was a hell of a environment when we ran 2-color 40” press anywhere north of about 5%. It was miserable running that press during the winter when we couldn’t open the bays. You know, unless your into that kinda thing, LOL.
I do not think I have any individual photos saved anymore, but I did chronicle my Mass G3 ATC build and all my modifications and projects in the forum. If you do a search under “Masso G3 ATC build update…” you may find a title topic that has what you may be interested in. I also have videos on my YT channel … TMDesign … going back to when I first started with my Woodworker and this hobby. Some of these videos also may have content that is relevant as most of my work - except for my Eames inspired house birds - has been machining aluminum.
I will also scan my drives to see if I have any photos specific to what you are asking.
