From my wifes phone Cast the ends in wax, maybe ¹/2 or 3/4 in from ends . Let cool , and then .mill. As a 80 year tool maker I have used this method a lot. Melt out the wax when finished.
Replying from my sisters phone Interesting idea with the wax. Seems like it would be easier to just cut some slots into some aluminum bar stock and “comb” the parts together for temporary support. Looks like the wood did the job though.
Always conventional mill the ends of box section and angle to solve the problem with vertical thin sections. Did you try the same conventional setup without the wooden clamp? High shear aluminium end Mills make a huge difference in this scenario.
Extruded aluminum can be a pain to machine. If I had something like that in our shop I would use a face milling machine and clamp the part upside down and make sure that the cutter was cutting from top to bottom. Also, our cutter was a 6" carbide insert tool and worked amazing on extruded aluminum. Great tutorial video.
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From my wifes phone
Cast the ends in wax, maybe ¹/2 or 3/4 in from ends . Let cool , and then .mill. As a 80 year tool maker I have used this method a lot. Melt out the wax when finished.
This. In some cases have covered or locked the part in place with low melting point alloy like Fields metal (contains no lead).
Replying from my sisters phone
Interesting idea with the wax. Seems like it would be easier to just cut some slots into some aluminum bar stock and “comb” the parts together for temporary support. Looks like the wood did the job though.
Fill the ends with wax or spray foam, melt or dissolve in lacquer thinner.
Great video. Sometimes the tricky setups are the most satisfying to pull off. Well done.
Always conventional mill the ends of box section and angle to solve the problem with vertical thin sections. Did you try the same conventional setup without the wooden clamp? High shear aluminium end Mills make a huge difference in this scenario.
Thank you Phil!
Very interesting Phil. Thank you!
Extruded aluminum can be a pain to machine. If I had something like that in our shop I would use a face milling machine and clamp the part upside down and make sure that the cutter was cutting from top to bottom. Also, our cutter was a 6" carbide insert tool and worked amazing on extruded aluminum. Great tutorial video.
Is it an idea to tilt the head, if you have a Brigeport of a sort
Brilliant, love it.
very useful, thanks
I was thinking you could use rubber sheet under wood
nice easy solution.....thinking out of the jar....or box...
Sandwiching two of them together didn't work?
Too obvious. lol
You only learn something new from a challenging job, run of the mill stuff you learn nothing but boredom. 😉
run of the mill ??? pun intended ???