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I weld tons of aluminum boxes. They are out of sheet metal and bent up, then I weld the corners. The problem is the finish work. The corners then have to be ground down and sanded to look just like the bent edges. I grind the edges by hand and sand them. It is very time consuming. I just wondered if anyone had any ideas about how to make the process go quiker. Any ideas on how to grind the edge welds or even use a router or something. Does anyone else have this problem? Does anyone have a solution?
Reply:Use a air grinder or electric grinder with a polishing disc . That will make your work SOOOOOOOOOOO much faster. Maybe you would like to sand it with an electric sander too
Reply:Is there any way you can fix up something where you can just sit the box onto an abrasive surface (like a belt sander or something) and be working on the next box while the weight of the box does most of the work for you?Smithboy...if it ain't broke, you ain't tryin'.
Reply:Aluminum is often machined with wood routers and bits. A round over bit may very well work for this application or at least make things go quicker.There are problems of course. One it that common routers are desgned to route non conductive wood. Aluminum being conductive will be a problem if it gets sucked into the motor. Another issue is control, take to much off at once and you will be struggling with the router. ON TOP OF ALL OF THAT THERE ARE THE SAFETY ISSUES. If you are not willing to take the percautions to keep yourself safe then don't evne think abotu this.Another option is to build a machine sort of like a beveling machine. That is a machine that is desgned to machine the corners of metal sort of like a jointer. These are pimaryly used to break sharp corners on plates and sheets. The part is slid over the table sort of like on a wood router table. The difference is that the machine is designed for metals and small removal rates. The idea here would be to use a round over mill in plce of a router bit. This tool driven by a motor or arbor that can handle the exposure to aluminum. The part in question is simply pushed by the cutter and along the fence. Very little of the cutter is exposed and the machine is stationary so you are relatively safe.Dave
Reply:I agree with Wizard that a router table approach would work. If air and coolant are available, it would help to set up a coolant misting system to keep the cutter from loading up. Also, look for the fastest and most powerful router you can find. I've used a Crap-sman 2hp plunge router with a 3/8" carbide round over (2 flute) bit to round over the edges of 3/4" aluminum plate. A more powerful router would have made the job easierThere are no small projects
Reply:80 grit sanding discs...a 4 or 5 inch angle grinder ..some canning wax and your good to go......zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:What process are you using to weld the boxes? Minimal weld means minimal cleanup.
Reply:Originally Posted by jaredc00I weld tons of aluminum boxes. They are out of sheet metal and bent up, then I weld the corners. The problem is the finish work. The corners then have to be ground down and sanded to look just like the bent edges. I grind the edges by hand and sand them. It is very time consuming. I just wondered if anyone had any ideas about how to make the process go quiker. Any ideas on how to grind the edge welds or even use a router or something. Does anyone else have this problem? Does anyone have a solution?
Reply:There is equipment out there to do this the companys name is Cimidthey have automatic equipment or you can do this with robotics easily. http://www.cimid.com/bkk.htmOr you can use a aluminum disc from Weiler - Altracutor a blending wheel or I have seen a CNC mill set up to cut the corners off with a radius cutter. RideKTM
Reply:A good quality flap wheel will grind down the high spots and blend the edges, in a sandpaper type way.Just my opinion, not from a book, just from the road.Howes Welding Inc.www.howesweldinginc.com |
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发表于 2021-9-1 00:59:51