How to Cut and Machine Square Aluminum Extrusions

Square aluminum extrusions are versatile materials used in various applications, from construction to manufacturing. They offer excellent strength-to-weight ratios, durability, and corrosion resistance. Cutting and machining these extrusions require specialized techniques and tools to ensure precision and safety. This article provides a comprehensive guide on how to cut and machine square aluminum extrusions effectively.

Sawing

Sawing is a common method for cutting square aluminum extrusions. Miter saws, circular saws, and band saws can be used depending on the size and thickness of the extrusion. For accurate cuts, use a sharp blade specifically designed for aluminum cutting. Always clamp the extrusion securely to prevent movement during cutting. Safety goggles and earplugs are essential for protection from flying particles and noise.

Shearing

Shearing involves using a shear or guillotine to cut aluminum extrusions. This method is suitable for straight cuts and produces clean, burr-free edges. The extrusion must be precisely positioned and aligned with the shear blade to ensure a square cut. A hold-down device is often used to prevent the extrusion from lifting during the cut. Proper safety precautions, including gloves and eye protection, should be observed.

Drilling

Drilling holes in square aluminum extrusions requires a drill press or hand-held drill with sharp drill bits. The extrusion should be securely clamped to prevent movement. Use a center punch to mark the drilling location and a pilot hole to guide the drill bit. Gradually increase the drill bit size to reach the desired hole diameter. Lubricate the drill bit with cutting fluid to reduce friction and improve hole quality. Wear gloves and safety glasses when drilling.

Milling

Milling machines are used to create complex shapes and contours in square aluminum extrusions. A rotating cutting tool removes material from the extrusion, following the programmed toolpath. End mills, face mills, and slot cutters are commonly used for this process. The extrusion must be securely fixtured on the machine table to ensure precision. Programming and tool selection are crucial for achieving the desired results. Safety precautions include proper machine guarding, protective clothing, and eye protection.

Turning

Turning involves using a lathe to remove material from the exterior of a square aluminum extrusion. The extrusion is rotated while a cutting tool is fed into the material. This method is suitable for creating cylindrical shapes, tapers, and threads. A chuck or collet is used to hold the extrusion securely. Tool selection and cutting parameters must be carefully considered to achieve the desired shape and surface finish. Safety precautions include wearing appropriate clothing, protective eyewear, and ensuring proper machine guarding.

Conclusion

Cutting and machining square aluminum extrusions require careful consideration of the extrusion’s properties and the desired outcome. By following these methods and adhering to safety guidelines, you can effectively cut and machine these versatile materials, ensuring precise and efficient results. Proper tool selection, workpiece fixturing, and safety precautions are paramount for successful operations.