tabs rule of thumb

[Rocketmachinist]

I just did some parts 4.5" by 4.5" by 1/8th in aluminum and had set my tabs to 4X @ .500 length and .015 thick and the part still broke out before it was suppose to. How thick would you guys recommend to keep the part located but not give me a hassle for breaking it out and deburring.

[Chris In-House Solutions]

It would depend on how you were holding the parts down. Aluminum is a fairly malleable material. I would say you would have to be at least double your thickness if not more.

[Sbarner]

I can get away with 0.02 thick tabs in certain situations. The flatness (if it's bowed or not) of the part is one thing that helps me determine thickness. If it's bowed alot, you're going to have a heck of a time even with thicker tabs. Perhaps try .025-.035, and see what that gets you. I don't know what your de-burr requirements are, but I find that after cutting the part out on the band saw, a pair of side cutters and a file makes quick work of tab remnants.

[Programinator]

Imo it all depends on your machining process. Sometimes try leaving material around the whole part and then cut tabs as a last operation. I just try to do as much machining as possible and then cut the tabs. It can be tricky though but worth the effort on certain parts