Need to X Cut Aluminum Extrusion & Get a Good Finish.

http://www.cncplasmacutting.org/

How smooth?

Wire EDM

Water Jet

Chop saw

Kramarat is correct. I use a plasma cutter on metal and the cut is as good as a punch.

The OD is round but has (8) cooling fins extending beyond the OD that make the outer shape irregular and almost a square. I need to sucessfully cut through the cooling fins and 1/2" thick wall with a smooth finish.

Sounds like a fuel rod casing .

So, we have a tube that is 5"ID and 6"OD, but we don't know how long the fins are.

Can you fully define the extrusion for us??????????? And give a flatness/parallel requirement for the ends????? How smooth is smooth?

The more you tell us, the more intelligent the suggestions will be.

I wonder if we're going into over think. I'm sure even better models can be had.

http://www.harborfreight.com/horizontal-vertical-metal-cutting-bandsaw-93762.html

It depends on quantities required

-if "small" quantity : proposing the "simplest" solution;saw cutting+deburring

-for "big" quantities: high speed disk saw cutter +deburring ( small quantity...)

The choice is ofcourse based economically on quality+quantity required...

Quite a few years ago I had an Italian made circular cross cut, cut-off power saw

(small bench mounted) that provided a mirror finish cut on aluminium sections.

It cut with a nine inch (ish) circular blade with very small teeth at 15,000 revs./min

Surprisingly, it was not at all expensive (compared to the UK machines) and I was

very pleased with the cut finish. Unfortunately I have long forgotten the name.

Any make with very high revs and small tooth blade though may probably be alright.

Hope this helps jt.

Guess who I bumped into last week in spec savers? EVERYBODY!

Any chop saw would need a negative rake blade to cut aluminium, or aluminum, safely.

CNC jim

Due to the large cross section, any saw blade would have to be big enough to accomodate it. A wood cutting table saw that can go through a piece of wood 3" thick needs a blade around 10" in diameter. Your extrusion size would necessitate a blade around 16" diameter, so a rotating blade of any kind would probably not be practical. I think maybe a bandsaw, being capable of accomodating that size cross section would work if you can find a blade with many teeth. I believe there is a diamond empregnated wire that can slice through any material cleanly. Maybe there is one for bandsaws? A laser cutting machine would work, but you probably need to use something readily available and not too expensive.

Metal cutting band saw with coolant and fine tooth blade. Then if needed belt/disk sander with correct grit. Clamp extrusion to cut. Use proper guides when sanding for proper angles. Allow for finish work if band saw cut is not smooth enough.

Hi,

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Aluminium profile cutting