NOW I REMEMBER WHY I HATE WORKING WITH ALUMINUM!

[chief38]

When ever I make a tool, jig or fixture I use Tool Steel 99% of the time. This week I had to make a measuring arm for a friends (owns a automotive repair station) tire balancing machine that does not exist. His machine is about 15 years old and was only capable of balancing up to 18" wheels. Now-days, that is considered small and so he was considering purchasing a new machine. Nothing wring with the old one - just limited to 18" wheel size. After talking to him for a while, he explained to me that the reason was the measuring arm was too short for todays larger wheels and so I said if that is the only restriction to your dilemma I can fabricate a new longer measuring arm for your machine. I ordered a piece of Aluminum Bar Stock from McMaster-Carr and it arrived Monday. The reason I used aluminum is that the measuring arm had to be strong but light weight. The original 4" arm was made of high strength plastic that I was unable to find a source on. The new arm is 9 inches long which will allow much larger wheels to be balanced (up to 22" he says).

So why do I hate Aluminum?? It clogs up every tool, grinding wheel, sanding belt, and drill bit. Files have to be cleaned just after a few strokes and belts have to be blown out with compressed air every minute or so. At least for me, I find it so easy to work with steel but a royal pain to work with aluminum.

PS: some might not know that when machining Aluminum, WD-40 works great while the normal lubricant/coolant use for steel should not be used.

The project came out great and now his wheel balancing machine is ready for the 21st Century of balancing! I'm glad I could save him the $4,500.00 the Snap-on Guy wanted for a new machine and since other than the arm there was nothing wrong with the existing one he buys a bit more life out of it.

PS: I HATE working with Aluminum!

 

[snowman]

At least for me, So why do I hate Aluminum?? It clogs up every tool, grinding wheel, sanding belt, and drill bit. Files have to be cleaned just after a few strokes and belts have to be blown out with compressed air every minute or so.I find it so easy to work with steel but a royal pain to work with aluminum.

Yes, sir; that sounds familiar. Been there, done that, as they say.

Andy

 

[NewToGuns17]

It's nice to drill though

 

[misswired]

As a long time machinist; kerosene is the best lubricant for machining aluminum. It's almost magical.

 

[DocB]

Yup, also known as pot metal. . .some people will argue that all day long. Good for making Ford pickup trucks. I drive GM so don't really care what they make Fords out of. The advent of aluminum seems to be around 1936 when those German daggers and swords went from being high quality amazing pieces to being junky pot metal stuff. It kind of reminds of the glass to plastic transition we have seen in packaging food products over the past 15 years. Why go to something better when you can go to something worse.

 

[cahotshoe]

Alloy and temper have a lot to do with the machining of aluminum. I bet you used 6061, the most common alloy. It is very gummy. An alloy in the 2000 series, 2024, 2011 makes small brittle chips that fall like rain. Aluminum is a magic metal, but you gotta know what you are dealing with.

 

[NYlakesider]

Yup, also known as pot metal. . .some people will argue that all day long. Good for making Ford pickup trucks. I drive GM so don't really care what they make Fords out of. The advent of aluminum seems to be around 1936 when those German daggers and swords went from being high quality amazing pieces to being junky pot metal stuff. It kind of reminds of the glass to plastic transition we have seen in packaging food products over the past 15 years. Why go to something better when you can go to something worse.

I have always considered Pot Metal to be Zink! ER I meant Zinc, thanks to Jeff423!

 

[Ole Joe Clark]

When ever I make a tool, jig or fixture I use Tool Steel 99% of the time. This week I had to make a measuring arm for a friends (owns a automotive repair station) tire balancing machine that does not exist. His machine is about 15 years old and was only capable of balancing up to 18" wheels. Now-days, that is considered small and so he was considering purchasing a new machine. Nothing wring with the old one - just limited to 18" wheel size. After talking to him for a while, he explained to me that the reason was the measuring arm was too short for todays larger wheels and so I said if that is the only restriction to your dilemma I can fabricate a new longer measuring arm for your machine. I ordered a piece of Aluminum Bar Stock from McMaster-Carr and it arrived Monday. The reason I used aluminum is that the measuring arm had to be strong but light weight. The original 4" arm was made of high strength plastic that I was unable to find a source on. The new arm is 9 inches long which will allow much larger wheels to be balanced (up to 22" he says).

So why do I hate Aluminum?? It clogs up every tool, grinding wheel, sanding belt, and drill bit. Files have to be cleaned just after a few strokes and belts have to be blown out with compressed air every minute or so. At least for me, I find it so easy to work with steel but a royal pain to work with aluminum.

PS: some might not know that when machining Aluminum, WD-40 works great while the normal lubricant/coolant use for steel should not be used.

The project came out great and now his wheel balancing machine is ready for the 21st Century of balancing! I'm glad I could save him the $4,500.00 the Snap-on Guy wanted for a new machine and since other than the arm there was nothing wrong with the existing one he buys a bit more life out of it.

PS: I HATE working with Aluminum!

What aluminum alloy did you purchase? Some grades machine really well, some are gummy. Aluminum is easy to machine, if you purchase a grade for machining and heat treating.

Have a blessed day,

Leon

 

[Ole Joe Clark]

Aluminum is NOT pot metal.

 

[Jeff423]

I have always considered Pot Metal to be Zink!

I think you mean Zinc.

 

[misswired]

Chief38, if you could have the pleasure of whittling on some inconel....you'd never talk bad about aluminum again.

 

[Ole Joe Clark]

I think you mean Zinc.

Aluminum is not zink or zinc.

 

[Jeff423]

Aluminum is not zink or zinc.

See post #7 above.

 

[arjay]

No good deed goes unpunished ;-)

 

[Protocall_Design]

If you get Tap Magic for Aluminum you will have a much easier time of it.
It is far better than WD-40 or kerosene. It also works great on all non ferrous metals like brass, copper, bronze, etc. I machine precision parts out of all metals for a living, so I'm not just repeating something I heard. I use this on a daily basis.

 

[chief38]

Alloy and temper have a lot to do with the machining of aluminum. I bet you used 6061, the most common alloy. It is very gummy. An alloy in the 2000 series, 2024, 2011 makes small brittle chips that fall like rain. Aluminum is a magic metal, but you gotta know what you are dealing with.

Yes sir - you are correct about having the 6061 - it sucks!

 

[chief38]

If you get Tap Magic for Aluminum you will have a much easier time of it.
It is far better than WD-40 or kerosene. It also works great on all non ferrous metals like brass, copper, bronze, etc. I machine precision parts out of all metals for a living, so I'm not just repeating something I heard. I use this on a daily basis.

Toolguy, I actually have Tap Magic in my Shop and forgot I had it! It was tucked behind the one gallon jug of WD-40 and when I went to fill up my dispenser for the WD-4o I found a few 5 ounce cans. As you can see, I've got a few items in there! This morning I neatened up the cabinet and so now I can see most of what is inside.

Any hints on how to keep Files from clogging up every 10 strokes? Someone told me baby powder works but I always forget to try it.

 

[chief38]

In case anyone is interested, here are a few pictures I took this afternoon of the part. It was made from 6061 Aluminum. Most of the critical machining was done on the inside and can not be seen here.

 

[cmort666]

I need a lot of specialized gear for macrophotography, and until recently, I couldn't afford to buy a lot of it. Even still, a lot of it either doesn't exist or is hellishly expensive.

While I use PVC for much of what I make, some of it can ONLY be metal, like flash brackets. I did a lot of reading on machining aluminum, and all of the things pointed out about aluminum came up over and over.

I couldn't afford a milling machine and the alternatives (at least until I bought a cheap drill press) were onerous.

Now that I've got a real job, I may invest in a mini-mill, and all of this information will be useful.

 

[JayFramer]

Ah-loo-min-yum.