Machining Cast Aluminum with an end grinder

[sam dupont]

I'm shaping some 1/4 inch thick cast aluminum. No idea of its composition.
My problem is: the carbide burr, (sc-3nf 1/4x3/8x3/4x2) packs full of material quickly. Is there a way to prevent this? A technique? A faster way to dig out the cutters? I'm spending more time digging than grinding

 

[1 Wild R/T]

First answer you should be using a burr designed for non-serous material..
Second answer, WD-40 helps.. So does Bees Wax or if you have an old milk crate grind a little plastic then aluminum, then back to plastic...

 

[khryslerkid]

Slow RPM and aluminum cutting oil. I always liked TapMagic.

 

[sam dupont]

Thank you for the tips! It is non-serous, (spell check got me too, what the hell is non-serous?). I thought about wax, but I got through the first step and wanted to make less work of it as I continued. I wasn't sure if I was using too fine of a NF burr or what was my problem.

 

[sam dupont]

Slow RPM and aluminum cutting oil. I always liked TapMagic.
View attachment 1338833

I wondered if it wasn't heating up. All I have is a 110 volt end grinder and it has one speed: Hang on! So I'll have to finally buy a air die grinder... woe is me (not)

 

[khryslerkid]

I wondered if it wasn't heating up. All I have is a 110 volt end grinder and it has one speed: Hang on! So I'll have to finally buy a air die grinder... woe is me (not)

4 1/2" sanding disk work pretty good on aluminum. Depends on how much you're trying to remove. They make them for aluminum.

Aluminum oxide sanding disk

4-1/2" x 7/8" A/O Resin Fiber Sanding Discs - 25 Pack

 

[zyzzyx]

Ordinary candle wax works on carbide burrs and band saw blades when working with aluminum. Grinding
or sanding discs will load up and clog! You just have to keep applying it as you go. It will melt as soon as
you touch it to the burr.

 

[padam]

They do make special burrs for aluminum that have deeper flutes.

 

[YY1]

Ferrous? (spell check issue)




Try a file card.

Doesn't stop the loading of the cutter, but makes removing the packed in material go way faster.

 

[khryslerkid]

Grinding
or sanding discs will load up and clog!

Not if you have the right ones.

 

[Virg464]

If your using a burr, high speed (HS) steel will load up a lot quicker than carbide. The HS burr will heat up and the alum will adhere to it, where the carbide won't heat as quick due to it's RC-90 hardness. Also, as posted earlier WD-40 works very well.

 

[toolmanmike]

Non ferrous carbide burrs.

 

[Virg464]

Non ferrous carbide burrs.

True, they will have a larger gullet in the tooth pattern.

 

[toolmanmike]

True, they will have a larger gullet in the tooth pattern.

I found my photo

 

[Jeremiah]

The only thing that worked on my winters cast Holley SD was Crisco. I tried everything in the shop and a fabricator friend advised I use Bacon grease or shortening. Although a bit messy, it works excellent.

 

[Photon440]

I found that a tub of nozzle dip (for mig welders) did a good job as well.

 

[toolmanmike]

I'm shaping some 1/4 inch thick cast aluminum. No idea of its composition.
My problem is: the carbide burr, (sc-3nf 1/4x3/8x3/4x2) packs full of material quickly. Is there a way to prevent this? A technique? A faster way to dig out the cutters? I'm spending more time digging than grinding

Sam, what's an "end grinder"?

 

[sam dupont]

Probably an ancient term first learned from my Grandfather. Some call them pencil grinders. End, as opposed to Side

 

[Scott Engelhardt]

My Pops also called them an end grinder