Grinding aluminum

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I have to round off some corners on aluminum angle. Can I use my cut-off wheel on my chop saw, or is there a special wheel I need to buy?Miller 252Miller Bobcat 225Lincoln MigPak 1801959 Hyster forkliftHarris OA torch
Reply:Do not use a stone it will plug up and over heatuse a flap or sanding type discBacked my CATMA over your CARMA oops clusmy me  What would SATAN do ?? Miller Trailblazer 302 AirPakMiller Digital Elite  Optrel Welding HatArcair K4000Suitcase 12RC / 12 VSHypertherm PM-45Rage 3 sawRusty old Truck
Reply:They make special grinding discs for aluminumBut they don't last long
Reply:Best to use a vixen file or carbide router bit.
Reply:There is some real danger possible from using regular "stones" to grind aluminum, especially on hard rock bench grinders.The CBS documentary show actually ran a story on some cases where grinder wheels exploded when spun up after having been used for heavy grinding of aluminum.Apparently the aluminum was being deeply embedded into the granular structure of the stone during aggressive grinding sessions.As the stone and the embedded aluminum cooled, the stone began to crack and fracture fissures propagated toward the center of the stone, ultimately leading to the stone shattering scattering at some later point.One victim featured in the story lost an eye and parts of his skull bone.  Luckily (if you want to call it luck), he had sustained no brain damage.He could have easily been killed. So remember, it might not be you who gets injured, it might be the next guy who uses the contaminated grinder.
Reply:buy a couple walter aluminum grinding disks,for a 5 inch grinderthey last pretty good, and the way they grind aluminum taking material off faster than anything in your life you cant complainfor just deburring and light grinding a sanding disk with 80 grit works greathttp://www.forgingtechnology.com/
Reply:I wasn't thinking of using the bench grinder but the cutting wheel on my chopsaw.Maybe I could try my beltsander?Miller 252Miller Bobcat 225Lincoln MigPak 1801959 Hyster forkliftHarris OA torch
Reply:Side loading a chop saw wheel could cause it to fail. We use a pedestal belt sander for aluminum all the time.
Reply:Originally Posted by WeldRiteI wasn't thinking of using the bench grinder but the cutting wheel on my chopsaw.Maybe I could try my beltsander?
Reply:Originally Posted by rlitman... Abrasive belts of all sorts (and flap wheels) are perfect for aluminum.
Reply:OK Thanks, I'll give my belt sander a goMiller 252Miller Bobcat 225Lincoln MigPak 1801959 Hyster forkliftHarris OA torch
Reply:Belt sander will work.For heavy grinding I use these. Work great.https://www.partsmaster.us/SitePages...px?Code=032040If you cant fix it with a hammer, it must be an electrical problem."Boy, everyone starts with a full bag of luck and an empty bag of experience. The trick is to fill the bag of experience before the bag of luck is empty."-Grandad circa 1990ish
Reply:If you keep the stone filled with tallow it will clean itself and stay sharp and will not blow up.  any welding store that I have been in sells the tallow just for this purpose.  Mac
Reply:For the job you describe, depending on how much material needs to be removed (and how fine of a finish left behind) a flap wheel and/or a non-ferrous grinding wheel, (each used with a 4.5" angle grinder) would be my hand-held weapons of choice.This non-ferrous grinding wheel works excellent on aluminum, with very aggressive material removal, and leaves no residue that needs to be removed before welding (so it works great for TIG welding immediately after):http://weldingsupply.com/cgi-bin/spi...||1|744

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4.15I would shy away from a carbide burr suggested earlier in this thread for the location you describe (unless no better tools were available) because it could be hard to prevent from skating right around the corner you're trying to grind off and into the side that you wanted to prevent from being marred.  (Although bracing the workpiece and/or your hands against something solid will be your best bet to probably prevent this from happening).  The angle-grinder tools mentioned above will not "catch".
Reply:Chuck up a roundover bit in your wood router.  I do it all the time on aluminum.  Be careful.this is using the router with a template bit to cut out electrical outlet holes in 3/16" aluminum plate.  Roundover bits with a ball bearing guide will work perfectly for what you are doing...Kevin / Machine_Punk from The Aerodrome Studio - Lincoln PowerMIG 210 MP - Meco N Midget w/custom welding station - Vintage Victor 100Current Projects: The Aerodrome Studio
Reply:Originally Posted by WeldRiteI have to round off some corners on aluminum angle. Can I use my cut-off wheel on my chop saw, or is there a special wheel I need to buy?
Reply:Originally Posted by WeldRiteOK Thanks, I'll give my belt sander a go
Reply:Originally Posted by Tool MakerIf you keep the stone filled with tallow it will clean itself and stay sharp and will not blow up.  any welding store that I have been in sells the tallow just for this purpose.  Mac
Reply:Originally Posted by WeldRiteI have to round off some corners on aluminum angle. Can I use my cut-off wheel on my chop saw, or is there a special wheel I need to buy?
Reply:I used my belt sander and it worked AWESOME. Thanks for all the suggestions.Miller 252Miller Bobcat 225Lincoln MigPak 1801959 Hyster forkliftHarris OA torch
Reply:If you mix iron and aluminum grindings you get Thermite.It will ignite and burn your whiskers off.
Reply:Originally Posted by farmer37If you mix iron and aluminum grindings you get Thermite.It will ignite and burn your whiskers off.
Reply:Originally Posted by Drf255Yes, but without an igniter or detonator, it will do nothing.  The Aluminum powder will violently pull the oxygen from any oxide salt of anything when lit.  Includes sand and water too.  IIRC, you need fine magnesium dust and barium peroxide as an igniter.
Reply:They make aluminum specific grinding wheels. They remove material like crazy and last forever (unless you use them on steel, or something else silly).... I still use a 5" wheel for my aluminum work and I bought it for a job back in june 2011.Exact same things go for those single cut aluminum specific carbide burrs; basically leaves a machined or routed finish.Last edited by MikeGyver; 07-09-2013 at 07:52 PM.Welding/Fab Pics: www.UtahWeld.com
Reply:Belt sanders work wicked for rounding edges on aluminumOriginally Posted by farmer37If you mix iron and aluminum grindings you get Thermite.It will ignite and burn your whiskers off.
Reply:for bench grinding aluminum you can use Green or Black Silicon Carbide wheels.They never clog and I've been using the Green ones for years. See PDF flyer below:http://www.google.com/url?sa=t&rct=j...49478099,d.eWU