Need suggestions on cutting thick aluminum

[Tooltime22]

I need help figuring out how to cut large amounts of 1.5" by 1.5" aluminum. So far I have been using a bandsaw but it is taking about 40 minutes to make one 16" cut. I am open to any suggestions. If you need me to further explain what I am doing I will.

Thank you

 

[readhead]

Explain further. Is it angle, tube or solid? What is the final goal?

 

[TurnipTruck]

Carbide tooth blade in a worm drive circular saw with Pam cooking spray once in a while. Maybe a couple passes at increasing depths.

spent seven years building aluminum skiffs/fishing boats/play boats/seine tugs

 

[Tooltime22]

Explain further. Is it angle, tube or solid? What is the final goal?

It is a solid block of aluminum. I wanted bar stock back when I started but that was all I could get. I will only use bar stock in the future.

The goal is to make wedges used to hold pipe in place. I rough cut them and then I go back and mill them to the right size.

I hope this helps.

 

[Firebrick43]

I need help figuring out how to cut large amounts of 1.5" by 1.5" aluminum. So far I have been using a bandsaw but it is taking about 40 minutes to make one 16" cut. I am open to any suggestions. If you need me to further explain what I am doing I will.

Thank you

A bigger high horse power band saw or pay a water jet to do it

 

[readhead]

More horsepower, different blade, different lubricant? Seems like a good candidate for a table saw but the same factors may apply. How many do you need?

 

[readhead]

I just noticed that the blade looks very fine for what you are doing. That may be the main problem.

 

[BigMike782]

I would use a circular saw and WD-40

 

[Tooltime22]

I just noticed that the blade looks very fine for what you are doing. That may be the main problem.

I will have to see if I have a course blade I can put in.

 

[mike93lx]

I would use a circular saw and WD-40

Same, just table saw. Multiple passes

 

[Firebrick43]

I will have to see if I have a course blade I can put in.

Rule of thumb is three teeth need to be in contact at any given point.

 

[mike93lx]

Rule of thumb is three teeth need to be in contact at any given point.

No more than 3 teeth, not at least 3, right?

 

[budget76]

No more than 3 teeth, not at least 3, right?

I believe it as least 3. More will just lead to slower cuts. If my recent reading on portaband blades was interpreted/remembered right. too many teeth in aluminum just clogs up the teeth in my experience

Aluminum can be cut with wood blades. I third or fourth the table saw or circular saw idea. With good ear muffs for sure.

 

[LopezBart]

The old tool & die guy that taught at the student-faculty shop used big skip-tool blades w/ lots of set for thick aluminum, and ran the bandsaw really fast. This is like cutting wood; crank up the speed. If you have it, a 3 TPI blade will work here.

I've used a carbide wood working blade in a circular saw for thinner plate; wear ear plugs + over-the-ear hearing protectors.

 

[MongoTA]

I don't use dust collection and cut aluminum plate on my tablesaw with a regular carbide toothed blade. Thickest I've cut is maybe 2" thick aluminum. Might need a few passes depending on your blade and saw, but it cuts nicely.

Thinner stuff, no problem, I'll transition right back to cutting wood. Thicker stuff like yours, if cutting quite a bit, I usually pull the blade afterwards and sharpen it. The blade will let you know.

 

[86turbodsl]

Use the right tool for the job. I'd be looking at 3tpi blade on a big bandsaw. Lots of people like carbide saw blade circ saws, i'm not a fan. Get the feed rate wrong and you'll regret it. Good luck.

 

[Firebrick43]

No more than 3 teeth, not at least 3, right?

At least three in contact no matter the position of the blade.

More leads to clogging

Some better blades have variable tooth spacing that drastically improves the quality of cut as it doesn’t form a consistent vibration/harmonic.

 

[Jswain]

If you could rip it to rough length on your bandsaw/or a tablesaw, then it looks like any mitre saw would do the trick to cut it to width

 

[cannuck]

To do this with a vertical bandsaw you need something that will self feed (I have Marvel 8s for this kind of stuff). Freehanding a little vertical is just too darn slow. So: suggest you go with a carbide blade in table saw, but use a misting spray of proper cutting oil (usually emulsion of oil in water) onto the blade to keep it from clogging. You would be surprise how quickly it cuts, but of course very wide kerf.

 

[RMERR]

I've cut a 60" X 60" piece of 1 1/4" thick aluminum in half with a circular saw with a Diablo aluminum cutting blade on it. Laid it on some 2 X 4's in the driveway and followed a straight edge. A slow cut for sure ( bring a Snickers bar) and something to pad your knees, but it worked great, got a clean beautiful 5' cut (and a ton of aluminum chips). I also keep a dedicated old small portable table saw around with an aluminum cutting blade for cutting smaller pieces, I've cut up to 5/8" thick, but I'm sure it would do thicker. I just can't bring myself to cut aluminum on my nice Laguna table saw with an expensive Woodworker II blade on it. I'm sure it would do it, but it just can't be doing that blade any favors.

 

[Steve from Socal]

Carbide tooth saw with negitive rake in a hand saw or better table saw. I have a 20" radial arm saw I got from Beechcraft that they used to cut extrusion, short of something like that a table saw or hand held circular saw is your best bet. I have vertical and horizontial band saws for the cross cuts a band saw or chop saw is ideal.

A lot of metal suppliers have large table saw to cut slabs of aluminum, it is by far the best method for sizing plate. 3~4 tooth per cut is optimal, that said, you will be hard pressed to find a round saw with that pitch for your needs, a 10" 40tooth is likely the best match.

 

[cruzer75]

Table saw with carbide blade! You can even do it in steps.

 

[Wamsutta]

Carbide tooth blade in a worm drive circular saw with Pam cooking spray once in a while. Maybe a couple passes at increasing depths.

spent seven years building aluminum skiffs/fishing boats/play boats/seine tugs

What happens if you try to make the same cut with a side winder?

 

[steel 35]

My go to is the chop saw for that; slow and fine tooth.
(Soon to be some teeth)

 

[mike93lx]

My go to is the chop saw for that; slow and fine tooth.
(Soon to be some teeth)

A 16" long cut in a chop saw?

 

[cannuck]

My go to is the chop saw for that; slow and fine tooth.
(Soon to be some teeth)

what kind of "chop saw" can make a 16" cut????

 

[mike93lx]

what kind of "chop saw" can make a 16" cut????

A really sweet one

 

[steel 35]

12" One.
It just takes two time's
My 1.5" Aluminum Tubing , solid & 80 /20 work great though.
Thought it looked little wide.

 

[Tooltime22]

I changed the blade out on the bandsaw with an 8 TPI blade (biggest tooth blade I have right now) and it is cutting so much faster. Thank you everyone for your help!

 

[danielbuck]

what kind of "chop saw" can make a 16" cut????

My Dewalt miter saw will cut 14", I assume there's probably larger ones out there.

 

[rustyzman]

For the future material purchase, contact Howard Precision Metals in Milwaukee. https://www.howardprecision.com/
All they do is sell sawn aluminum plate and they can supply it saw cut to ±.005" if you need it. Doesn't solve this problem, but maybe next time it will.

 

[Monza Harry]

When shopping for a blade go to an industrial supplier with a knowledgeable sales staff [at least 1 available] and get a blade specifically for aluminum.
The blade will still be available in the required pitch [3 teeth in contact minimum] you will need a pretty coarse blade for that length and as mentioned above a vari-pitch like a 3-4 TPI (Firebrick43) with very deep gullets and a larger set, and potentially a "zero to negative rake" (as Steve in socal mentioned) as aluminum cuts pretty fast and can fill the gullets which will cause the blade to vear off to 1 side.
Coolant is also needed at the length stated I would add a nozzle or 2 in the center area of the cut as well as the standard leading and trailing coolant jets/nozzels. These steps should increase your precision and efficiency. Oh and bring all of your patients. Harry

 

[cosmokenney]

I heard you can cut AL with Plasma??

 

[Firebrick43]

I heard you can cut AL with Plasma??

Cutting 1.5” thick aluminum is going to require a a 300 amp plasma cutter and h2 or h35 gas.

Not something real common in home shops or even many job shops due to cost.