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How would you do this, Any slitting saw tool recmondations


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I m having problem cutting these slots. Just think this part as giant heat sink.

 

Material is Alpase K-100 Alum tooling plate

Part Size 12 x 13 x 3 " thick

Slots are 25x .236 wide 2.7 " deep with full radius on bottom

 

 

I m using a 8" dia .236 thick slitting saw stagger brazed tip with full radius from Lexington Cutter. It s not working that well.

Surface finish is terrible.  and the cutter is putting to much stress in to the material that part bow out of flatness and walls get taper. This material should be preety stable and not move like that.

 

How would you do these slots? any new slitting saw recommendation please.

 

Thanks in advance.

 

post-22284-0-94949900-1424885653_thumb.jpg

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I am pretty sure this will be no help, but I would just hand it to the EDM guy..

 

If I had to do it.. I would buy a full radius saw that wasn't full slot width..  like 3/16 width then cut the middle of the slot and side trim for size.. by cutting on only one side of the slot you could probably attain a better surface finish.. and less stress .. although if you ask me.. removing all that material in that shape.. its going to want to bow no matter how you cut it.

 

Then I would use the full radius to profile the full .236 radius at the slot bottom..

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I am pretty sure this will be no help, but I would just hand it to the EDM guy..

 

^This. You could probably get an EDM guy to wire it for less than that 8" saw cost. Although, if you have 1000 to do, gonna need to figure out the saw.

 

Worst case scenario if wire isn't an option - use your existing saw to cut every other slot. Then fill them in with a low melting point metal, and cut the rest of the slots.

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  • 2 weeks later...

1) What kind of part quantity are you looking at?

2) How are you holding the part?

3) can you flip the part end for end?

4) how long is the tool holder? 13"?

5) is the machine 40 or 50 taper?

6) are you machining the slot in one shot?

7) what tool motion strategy are you using?

8) does the tool chatter? why?

 

Edm is a great idea but pricey

extrusion is a great idea, but I think this is cast aluminum plate.

Casting maybe?

Water jet through 12"...

 

Here's a tool I'd look at.

Ph horn

dia - 7.8740 w - .236

holder - 383.0200.40.06

insert - R/L 314.0320.20

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If I was forced to use a saw cutter, I would take depth cuts in multiple passes and finish the slots at each depth. 

The part would be more stable and probably won't chatter.

 

For example finish each slot at .200 deep

then at .400 deep 

etc...

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