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So I tried milling some Aluminum sheet today, 0.125" thick... typical thickness of front panels.

First Try: Use my 1/16" flat end mill.

Push START button... whirrrr.... CNC head moves, plunges and makes first circular 1/8" hole cut. Whooppee!

Then draws the IEC jack square outline. First pass okay... second pass, dig in deeper, then move.... SNAP. My BIT BROKE!!!

Within 10 seconds... I broke this bit!!!! Bummer.

Hmmmm... I then tried some surplus solid carbide bits I got from Harbor Freight. I can plunge and drill through with no problems. As soon as I move horizontally, it breaks.

Okay, let's try a bigger bit... I think this one is just a bit smaller than 1/8". Working good. I was able to dial in what inch per second the machine will travel.

Lesson learned: The material must be adequately and securely clamped!!!! Otherwise, the aluminum sheet will move and that will destroy the work.

Okay, got my confidence up... tried back my other 1/8" mill bit. Then within 5 seconds, it breaks!!!! ARRRRGGHHH... My second good bit broke in only a few seconds.

Lesson learned: These bits are perfectly fine for wood and MDF, but totally weak when it comes to milling even soft aluminum.

I need to get bits specifically designed for milling metals... made from the strongest material possible (solid carbide).

I'm a little bummed from this testing. I gotta make this work. After all, this was the whole point of investing in a CNC machine... to be able to mill aluminum panels. I don't really have any interest milling wood or MDF.

I have to do more research into this.

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I'd think you'd need a specific cutting bit, meant to cut horizontally after plunging...

http://www.amanatool.com/cncroutingdeta ... 51402.html

Something like that?

But yeah, solid carbide.

Scott

Yeah.... okay I just bought (2) of these aluminum cutting bits. We'll see how it works out when I get them. Thanks.

I probably need to get some lubricant too. Right now, just using WD40.

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