OT: Cutting Aluminum Stock

DerbyDad03 · 2010-04-15T15:38:38+00:00

On occasion, I need to cut aluminum stock, both 1.5" x 1.5" x 1/8"angle stock and 1" x 1/4" flat stock.I have always used one of those metal-cutting wheels in my 10" DeltaMiter Saw, similar to this: other day, I was watching "How It's Made" and they showed theprocess used to make Carbide Tips saw blades. They started with theraw steel and followed the process through to the final product.At the end of the segment, they showed a carbide-tipped blade in amiter saw cutting through a steel rod with the voice over sayingsomething like:"And when they're finished, they're strong enough to cut through thesteel that they are made from."Somehow, I'm reluctant to start using my carbide tipped blades to cutmy aluminum stock. The thought of the teeth grabbing the angle ironjust scares the bejesus out of me. But if they can be used to cutsteel, aluminum should be a breeze.Am I right to be afraid, be very afraid?Are the cutoff wheels, even with the melting and subsequent filing/grinding that I have to put up with, still the best option?Thanks!

Apr 15, 2010 22 Replies

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DerbyDad03 16 years ago

I'd like to share what the guy at the local "Saw and Knife" store just told me and ask for your Based on the thickness of the material, 60 TPI is probably the highest you want to go. Above that you run the risk of melting the stock and have it weld back together behind the cut. 80 TPI and above is for very thin material.

Best tooth design is Negative Hook Angle, Triple Chip Grind. Alternate Top Bevel, especially with a Positive hook will dull very, very quickly.

Cut the Angle stock legs down.

Cut the 1" x 1/4" flat stock "standing up" - clamp it so the the 1" surface is against the fence.

According to that info, the $59 Diablo non-ferrous 84 TPI blade that HD carries doesn't sound like what I want to use. The Saw and Knife place has a $79 blade in stock that fits the specs he laid out.

Your thoughts?

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Chasgroh 16 years ago

...I use a 60 tooth Tenryu on a 10" Makita chop saw that goes with me to jobs...I cut aluminum regularly (thresholds, shower door kits, etc). It took awhile to "get over" the concept, but now I don't hesitate at all. Steel, though...nah, too many broken carbide tips for me...you'll be fine with a good quality blade...keep the feed rate down...

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Father Haskell 16 years ago

The POS Porter Cable 10" blade that came with my chop saw won't cut wood worth a damn, but it does fine in my table saw for cutting aluminum channel. It's an intimidating operation if you've never done it before, but easy once you try.

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