Cutting Steel Router

Too vague.

A rotary file in a Dremel tool will do it.

Carbide Rotary Files

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Yeah Lyn, I agree too vague mate, Okay then, here's what I have. coated steel 1/8" thick, width of cut 5/16" and depth of cut 5/8". There is also approx 1" between cuts with a total of 8, one after the other. A mate of mine has a bench drill, my hope is to set up a system where I can automatically push 8pcs through as describe, at a time. The bit will have a oil drip system running on it. Is it possible? and if so what would be the best tip to use as far as speed, longevity and safety goes

There's nothing "automatic" about a drill press. This is an accident waiting to happen.

I don't understand a 5/8" deep cut in a 1/8" plate. Do you intend to stack the plates?

Sorry, I have a very literal mind. Your description still doesn't make sense to me.

Maybe a sketch/picture?

This sounds very dangerous to me, even for an experienced metal worker.

What about a table saw with a steel cutting blade, like a chop saw uses?

Milling machines, as shown are expensive to buy. There are milling vices that are available, but in the size that I understand you will need, this will also be expensive.

What about contacting a machine shop, and throwing them some cash?

Auto drill makes these...

http://www.autodrill.com/

So you're cutting 8 notches 5/16 x 5/8 in the edge of 1/8" coated steel? I'm surprised somebody hasn't jumped in with water jet or laser cutting . I suppose if it's zinc coated, laser is out. If you have many of these, milling is going to be very time consuming unless you have CNC.

Edge.

This is not impossible.

Tungsten carbide burrs? Do you intend using these in a standard hand held router? You will have to take care in case the cutter kicks back. Feed rate will be slow, I've used these on stainless sheet & they cut OK.

Here's another example of "two countries separated by a common language".

Winston said it first.

It is called a milling machine, or just mill.

I have made a little ol jpg of what I am looking at but, how does one upload a jpg

"how does one upload a jpg"

Post a reply & select the picture icon then browse to your jpeg location.

A milling machine and a good machinist is what you need. Cutting steel with the correct tools is why you need training in machining. Good training will save you stock, coolant, fingers, and prevent a lot of headaches and anxiety for you.

I assume it would be a CNC router.

Had quite a bit of experience in the shipyard using CNC router (Shoda) to cut softer nonferrous metals, such as copper/Nicole, silicon/bronze and aluminum. We had it on MDF vacuum tables, so we could only limit our cutting fluid usage.

Because of the high speed of the routers we could not use carbide tooling, these would not hold up, we use standard high speed steel cutters. And because of the high speed we calculated chip load, we did this to carry away the heat of the cutting.

Cutting anything harder such as carbon steel or stainless, burnt up your bits.

Set upon the router was quicker, and table was quite a bit larger than your milling machine.

The first thing that came to mind was a pantograph, and the second is an old fashioned duplicating machine (a 3-D mil). I guess now a days everything is CNC/CAD. The equipment would depend on how big a piece you are trying to shape! There is a lot of used equipment around that is for sale.

Routers will work non-ferrous metals - they will even make very shallow cuts in cast iron. However, they are no good in steel. A router turns at 15000 to 25000 RPM.

Moreover, a milling machine for any affordable price will not make a 5/8" deep cut. You can get cheap milling machines, made in China for about $US 2000.00 that could probably make a 1/8" cut. Maybe. Check out Island Freight. (disclaimer)

I wonder how many of these 8-slot gizmos you need to make - is this one-off or are you going into production?

I wonder what are the dimensions of the 8-slot gizmo? What I'm getting at here is the amount of material that remains behind the slot.

I wonder what are the tolerances required? Could you make these by hand? This would involve drilling 8 holes at the required position singly in each plate (or maybe stacked - depending on the dimensions of the plate) and then cutting out the slot with an angle grinder. A 4-1/2" angle grinder with a thin cutting disc (Walter "ZipCut" 1/16 thick) would quickly cut the slots. Touch up with file.

Thanks a lot, you guys are the best! I am going to try and upload my picture, usually a pic is worth a thousand words so let's see what happens. Also, I am now an American citizen and have been for one hell of a long time, that being the case everything must be Made in USA. My mates little ol shop uses only American re-furbished machines, the thing about them is that they are old but really, really good. Thanks for the heads up on the upload Nigh, nice to get help from my old neck of the woods

/Users/screen-fx/Desktop/Cheesewing/table drill rectangles.jpg

Well I tried that on my mac and didn't see the green camera Nigh mentioned but, I have just opened internet explorer and see it so here goes. By the way it ain't no picaso

Will it look like this?

OK, it's close.

I think that it is more like this:

The OP has presented us with a picture of a Taiwanese-manufactured drill press.

The OP is asking about the process. For this we need a picture of the product - not a picture of a drill press.

What quantity - one-off or continuing production?

What dimensions?

What tolerances?

You're right. I had the numbers backwards.

I believe we all can agree, the tolerances on a drill press, are no where near where it should be for accuracy. Both in Spindle, and table tolerances and stability.

Actually Lyn no, First of all mate I don't want to get knocked off, that being the case the pic here is the closest I can come to to the real thing. What i am tryjng to do is come up with a way that I can produce whatever quantity is needed, as orders come in "no inventory". The samples I made were really well rec'd only. I had to use a drill and drop saw, the process seems too labor intensive and time consumiming, this is why I am trying to find a more productive and competative process.

My apologies for the run around but, with everyone and their grandmothers on line, I fear on saying to much, specially when one has kids to put through school + my country needs the jobs.

One of the things I got out of Baffled was the possibilty of using an angle grinder. I took that a little further and looked up some old custom drop saws that could possibly take two blades, hey it's cutting down production time and cost, a little. Now if only I could put 5 x 1/16 blades together, (just being a little crazy)

Have a great day all

We were not aware of the required tolerances,....... my earlier post can be ignored.

"I am trying to find a more productive and competative process."

Each slot would require about 6 tons of force to punch.

Can you give us some numbers that you anticipate orders to be? 10s, 100s. 1,000s? If only 6 tons of force would be required to punch them, an automated press would knock them out with nice finish, and low labor. JMHO.