Shell Milling Aluminum – Lube?

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Shell Milling Aluminum – Lube?

Home Forums Workshop Techniques Shell Milling Aluminum – Lube?

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  • #799750
    James Hall 3
    Participant
      @jameshall3

      Thanks to Rapid-Metals Easter discount I obtained the bulk of the materials for my intended Farm Boy build at a bearable cost.

      There are three large hunks of aluminium which together form the ‘frame’ of the engine. I bought them oversize so as to be sure of accurately arriving at finished o/a dimensions, but this leaves me with quite a bit of material to remove externally in addition to the required ‘hollowing out’.

      With this in mind I bought a 50mm shell mill (complete with R8 arbour for my SC3 mill) at a price so ridiculously low that it could be discarded without too much pain if the quality turned out to be poor. I also ordered a set of the highly polished inserts specified for machining aluminium. I have to say that I’m delighted with the bit of kit so far getting a mirror finish and capable of removing material at an enormous rate. Haven’t tried it on steel so don’t know how it will perform there.

      Finally, I’m getting to my question. I normally use paraffin when machining aluminium – as per the books – but don’t know if it is necessary with these inserts. I’d be happy if not as the rain of ally chips is bad enough a mess without the added paraffin.

      Given the amount of ally to be machined when carving out these frame pieces I also wonder if it would be good to invest in the similarly highly polished end mills intended for ally, and if so, again, whether paraffin as cutting fluid is advised.

      Advice would, as usual, be much appreciated.

       

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      #799752
      Steviegtr
      Participant
        @steviegtr

        I usually use WD40 or parafin. Although sometimes with the shell mill I use normal cutting oil.

        Steve.

        #799773
        JasonB
        Moderator
          @jasonb

          Parafin in my usual choice, you really don’t need much and if the chips are left for a day it will evaporate. I have recently taken to using a fully synthetic cutting lubricant when doing long milling jobs on the CNC but if just hand (brush) applying I would say stay with the parafin. Cutting dry you may find the surface picks up.

          Certainly worth getting say  6mm and 10mm Carbide cutters intended for aluminium either two or three flute and standard length as you can run them fast and take off quite a lot. Best to use a cut that uses most of the edge so 15-20mm and 1mm sideways is possible with the 10mm and 10mm x 0.75 for the 6mm. Again just a drop of parafin before each pass. You might want a long one to get into the base but they can chatter a bit more so reduce the cut.

          #799778
          David George 1
          Participant
            @davidgeorge1

            Paraffin is the way to go on aluminium. I bought a 4LTR container from B and Q a couple of years ago  and it is still going strong. I have a small plastic squeeze bottle which I fill from the larger container and it is surprising how little you need. Just brush the swarf clear whilst cutter is not running.

            David

            #799782
            Robert Atkinson 2
            Participant
              @robertatkinson2

              I use a tiny amount of WD-40 brush applied when cutting aluminium. I use a two insert indexible end mill for facing surfaces (I’ve a small mill). A quick wipe with a brush over the surface and inserts before each pass. For solid mill I just “wipe” the cutter with a flat stiff bristle artists brush. The long handle compared to a acid or glue brush keeps hands etc away from cutters and moving parts.
              I bought a 5l container of WD-40 years ago. it goes a long way. Parrafin will also work. If you don’t like the smell you could try de-odorised white spirit with 1 or two percent of oil added.

              Robert.

              #799791
              Ian Hewson
              Participant
                @ianhewson99641

                As you are getting a mirror finish already, why do you need lube?

                My farm boy was machined with metal from the same source without lube, no sticking on the cutters. If there’s no problem why fix it.

                good luck with this interesting project.

                Ian

                #799810
                Robert Atkinson 2
                Participant
                  @robertatkinson2

                  Problem is if you don’t use lubricant and a bit of swarf sticks to the cutter on the final cut it’s too late.

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