I will be using 1.25 inch diameter square aluminum tubing for a consumer product and will need to cut to length, bore holes for a set screw, and debur for powder coating. I will receive the aluminum in 8-10 ft lengths and will cut them up to 6 ft. can anyone offer advice on machinery needed? i do need precision need a cost-effective solution. (image is conceptual only)oh, did I mention, i am not a machinist in any way..yet)
Cut your pieces on a regular 4" bandsaw $300. A small mill / drill can square the edges $1000. because your parts are made to tight tolerances you could make a drill guide jig and drill with a 18 volt drill $100.
A shop filled with the miscellaneous bits and pieces needed Priceless. its not hard.
Anthony.
PS welcome to the site.
1¼" Dia. brings "round" tubing to mind but I suppose you could mean 1¼`square tubing.
You mention "boring" holes for a setscrew, what is the wall thickness?
What is the "setscrew" size.
Need more info.
Edit, Disregard the above, I found the explanatory OTHER post! (still wondering about 1¼ Diameter)
thanks for responding- the wall thickness will be 0.08 on one extrusion and at 0.12 in the other. set screw size tdb by engineer, the 1 1/4 is the width -sorry it is square not round.
That wall thickness in aluminum is not going to be sufficient for a set screw of any significant size. You would be advised to TIG weld a boss in each location where you need a set screw and then tap it with an "STI" (screw thread insert) tap, then fit a Helicoil or Keen-sert steel thread insert.
Just a thought, is there any way you can get the stock delivered in lengths of either 6' + or 12' + ? It would really cut down on the amount of material waste and probably bring your costs down.
-Ron
(08-16-2014, 10:23 PM)PixMan Wrote: [ -> ]That wall thickness in aluminum is not going to be sufficient for a set screw of any significant size. You would be advised to TIG weld a boss in each location where you need a set screw and then tap it with an "STI" (screw thread insert) tap, then fit a Helicoil or Keen-sert steel thread insert.
Ken, I somehow doubt if the term "setscrew" is being used as we know it. Are you familiar with the type of extrusions she's talking about.
EdK , is there some way you can consolidate Marci's posts so there can be some continuity of reference?
(08-17-2014, 12:31 PM)stevec Wrote: [ -> ]...
EdK , is there some way you can consolidate Marci's posts so there can be some continuity of reference?
Steve,
I deleted the duplicate post yesterday, if that's what you're talking about.
Ed
No Ed, all the different titled posts that are all about the same subject.
Actually, If she has an engineer to "spec things" why is she bothering us?