I have to countersink some pre-drilled holes in ~.1" thick VERY soft aluminum. The holes are for 100 degree #6 flat head screws. I would appreciate any suggestions about the best type of tool to use, best rpm, etc. Last time I seemed to swage as much as I cut and I was using a new, supposedly sharp tool.
Thanks
I'm sorry. It sucks to be you.
Go slow on the rpm. A fluteless countersink might be good, and a good lube really helps. How many holes? If it's only a few, you might be time and money ahead just using a sharp corner end mill running up and down the angled surface inside the hole.
Later,
Charlie
Jack, I like the single flute Ford brand single flute countersinks.
is this on machine or by hand
CLIP
CLIP
With super-soft alum. this seems to be a key "ingredient" as they say... The best, most ridgid machine with brand new, super high-trech tooling will have problems in soft aluminum if it's not lubed up...
Personally, there is a lube sold by TapMatic (I think) that they suggest for alum. tapping. I've found it to be the best lube I can find for some aluminim drilling processes so it may work wonders for you too...
I have A-9. Someone recommended that. These parts are single sided aluminum core PCBs. I'm very concerned about contamination and delamination. The A-9 didn't seem to harm the boards before.
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