Cutting rings

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I have a project where I need about 10,000 rings 3/8" long cut from 1" sch 40 aluminum tube. They will need to be deburred as well. Thanks for the input.
Reply:Sounds like a big project. What cha makin?Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:I guess I'm wondering if they have to be cut from tubing?  Deburring can be done in a tumbler if you don't need to keep the hard edge.
Reply:Art work;-)What other options other than tubing would you suggest?
Reply:I'm just a solderer, but if they are not structural and you just need a loop there may be some other options.  If you have some flexibility on the thickness (length) stamping may be an option, or even rolling.
Reply:What about a cold cut saw.
Reply:I apologize for this link but it makes sense,http://www.alibaba.com/product-gs/24...um_sleeve.htmlAppears you can buy them cheaper than make them, Chinese here but good place to start.
Reply:Really depends on the finish requirements.Could be as simple as a bandsaw with an auto feeder. See this thread down around post 10 to 12:  http://weldingweb.com/vbb/showthread.php?t=150171A cold saw may yield a better finish than the bandsaw but you'd be at the saw a while.These could also be done on a cnc lathe with a sub-spindle and bar feeder pretty quick. Then all surfaces could be cleaned up and chamfered.
Reply:GjertsonHave it done in a CNC Screw-Machine. Perfect dimension and edges.Opus
Reply:Originally Posted by OPUS FERROGjertsonHave it done in a CNC Screw-Machine. Perfect dimension and edges.Opus
Reply:Profit, 100 cuts per hour equals 1000 cuts for every 10 hours,1000 cuts every 10 hour equals 10, 10 hour days to get 10,000 pieces. Cleaning off the WD40 which by the way is never used on Al and deburing in a tumbler which you will have to build or pay for. Which also works poorly on Alum because it is so soft. Let say takes another 10 hours. That equals 110 hours to build 10,000 pieces. At $10.00/hr to break even you have to sell them for $1,110.00. or .11 each.It is up to you. by the way remember the cost of the 1" sch tube.If my math is wrong I am sorry but I have never met a Welder that did not want to make a profit.
Reply:I'm curious, what's your actual question?
Reply:I did a little follow up and WD40 and aluminum. I was wrong and learned somthing today,  I have always believed that welding over WD40 was a proplem.  My point was simply to  provide a check  to make sure that making 10,000 Alum. rings might not be cost effective as buyng them premade. If CNC can produce the rings cheaper than buying them then great if not why not buy them.
Reply:Originally Posted by Mick120For all my aluminium extrusion cutting, I use a cheap miter saw, fitted with an aluminium cutting blade.Like a hot knife through butter, just keep the blade lubricated with WD40 or similar.....set up a stop and you'd have them cut in no time.Deburring would be quickest in a vibratory tumbler.....lapidary supplies like these would be cheapest option.http://www.aussiesapphire.com.au/ind...oducts_id=1761.....
Reply:Originally Posted by Mick120Not so....not from my experience anyway altho, I only use it for aluminium.I use a Maktek (cheap version of Makita) and, the thing cuts brilliantly, fast, and clean.You do have to keep the blade lubricated tho.
Reply:Thanks for all the advice so far. These rings get welded together to make an oblong sphere, light fixture type thing. The dimensions need to be pretty close to so the design works. I didn't do the design I'm just stickin em together. Every machine shop I talked to today said they're out 2-3 months. More calls tommorow. Last time they had these done it was .32 a piece.
Reply:Why not simply cut the tube into 10 (or even 20) equal length sticks, tack the ends together in a square block and cut them on a good horizontal band saw? 10,000 pieces now only takes a 1,000 (or 500) cuts. Not fun but defiantly doable in a day or so.  I use to cut parts that way all the time working in a piece rate shop. That was the only way you could make any money If 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:I did a similar job a few years ago and needed about 1,000 rings of steel pipe. Automatic band saw is the cheapest route if you can deal with the burr. For clean cuts a cutoff lathe is the way to go.Ian TannerKawasaki KX450 and many other fine tools
Reply:Art project. Cool. This plan would be all sorts of wrong in so many ways for a Pro. If you have access to a particularly large and scary band saw, look into bundling the tubing. If you can bundle and secure 10 pieces of tube, you only have to make 1000 cuts. 100 tubes, 100 cuts, so on so forth.At 3/8", you need (3/8" + width of blade")x10,000 inches of tube. Assuming about 1/16" for a band saw blade, you are looking at 7/16" per piece. That by itself is 4300 inches of tube, or about 36 pieces that are 10 feet long. The rings minus the "crust" add up to 3700 inches.  I always have to double check that sort of math. Yeah, its bit me plenty.The real trick is getting the tubes in the middle to not move while you are cutting. Could tack all of the tubes together at one end and strap them together in a few places so that they were secure enough to move. Other options exist, from duct tape to chicken wire I am sure. Much more set up time, but vastly less machine time. Once all cut, rent or obtain a cement mixer. Buy a box of walnut shell blast media from Harbor Fright (tm). And go to town.Now the real secret here is beer. I have never had too much use for the stuff, I have a more refined palate. I prefer a stronger mix with a reduced frequency.  However, I can rustle up a crew fast with a full cooler.
Reply:Originally Posted by shortfuseI guess the aluminum is much softer and most metal cutting threads have been related to cutting steel.  Thanks for sharing your experience.
Reply:Leave the cutting to band saw . One question, what's your deburring tool ?