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Tips for drilling aluminum plate with a hole saw

Redboy

Redboy

a few good watts
Okay, I've got the following:
  • 6061 aluminum plate nearly 1/4" thick
  • giant caps (2" and 2.5") to mount through said plate
  • A brand new set of Morse Master Cobalt® Bi-Metal hole saws
  • drill press
  • more ambition than brains

What do I need to know before I head into this?
 
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Pilot hole ? Center punch first then drill a 1/8" hole to guide the hole saw to keep it from "drifting".
 
jbrainey said:
Pilot hole ? Center punch first then drill a 1/8" hole to guide the hole saw to keep it from "drifting".
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Good! I was planning to do that, but good to confirm.

Should I use a cutting oil with these saws, or can I skip that?

Speed - fast or slow?
 
You can use cutting oil, but usually not needed with aluminum. Use the slowest speed you have on the drill press, and BE SURE to clamp your work. It will try and spin with a hole saw...
 
Cutting wax, if you can find it, and tape over all the exposed aluminum near the intinded hole.

Drilling aluminum makes these long threads of aluminum that will swirly-scratch everything near the hole. Guess how I found that out.
 
OH.. and light pressure.. especially when you get close to being through it.. of course you know to back the work with a piece of wood..
 
Aluminum is very soft so you don't need oil but If you cut too fast it may clog up the teeth of your bit. If you want a clean cut you should probably drill slowly in little steps and clean the shavings away between plunges. Medium speed and a sharp bit.
 
+1 on the Slowly and the Clamps! Don`t ask how I know. The tape is a great idea as well. I normally tape out about two inches or more depending on the size of the piece. Drill slowly and bring the bit out of the aluminum frequently for a cleaning.
 
Clamp the hell out of it! It is amazing how scary a whirling piece of aluminum is. If the part is allowed to move even a little you can end up with chattering and a nasty hole.

Whats the slowest speed on your press? If it is a woodworking drill press it might still be too fast. Cutting wax is a good idea, I haven't used it.

Make sure your hole saw spins "true" almost every freaking hole saw I own is out of round and doesn't make flawless holes.

If all else fails, return the hole saw and ask a machine shop to do the holes. Chances are the hole saw wasn't cheap! Sometimes machine shops take pity on us mortals.

Good luck dude.
 
CarlV said:
Your best advice here, teeth and bits filled with aluminum really ruins your day.


Carl
Click to expand...

Sometimes I run a vacuum against the hole saw while cutting, it helps a lot. And as far as the wax goes, I forgot, that's for hard to machine metals, with aluminum, you're good w/o.
 
avionic said:
Not me ..I'm using and offset end mill cutter.Plan on using a milling machine to fabricate the entire plate of .250" aluminum plate.
Click to expand...
Can you expand on that a bit? I don't know squat about what you just said... :stupid:
 
Sure.I'll see if I can find a photo..But it is and adjustable cutter .
 
Must be nice to have access to a milling machine... Wished I had a first born to give him up to own one..
 
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