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Old 01-23-2010, 11:56 PM #1
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Default Question machining Cu

I'm still working on my solid Cu host. But I keep running into a problem machining the copper.
I started out with a 6" X 1 1/2" bar stock.(not sure if it pure Cu or not, bought it off my scrap pick-up guy)
Every time I get deeper then 1" with the 3/8 boring bar, I start getting terrible chatter.
I have tried Protap Gold, Tap-matic GP and Tap-matic Al ,cutting fluid with the same results.
Anything that stops the chatter, just gums up the carbide blade on the BB.

Anybody know of something that works good on Cu?

The Protap Gold worked great until I started with the boring bars.(made a hell of a mess although) I have never made anything close to this large with Cu. It sucks!


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Old 01-24-2010, 12:04 AM #2
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Default Re: Question machining Cu

When I was machining Cu the other day, I used light cuts, Carbide bit and WD40. Light cuts are needed because of the gummy nature of this metal.
I don't have special bits for non-ferris metals.

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Old 01-24-2010, 12:50 AM #3
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Default Re: Question machining Cu

Quote:
Hemlock_Mike; I don't have special bits for non-ferris metals.
Mike,
I don't either. Never had the need for them. I work mostly with Al. or Alpha Brass or Brass/Ni alloy.
The TiN and TiAIN bars run around $400/10 Pc. set
And the C-2 Black ceramic Boring bars run up to $1300 for a complete set.
After messing around for almost a month, trying to get this host right, $400 don't sound bad.(I'm sure this won't be the only project i'll use them on).LOL
Quote:
I used light cuts, Carbide bit and WD40
I've never tried WD-40.
I'll check it out. Hows does it work on Al. and A/Brass-L/Brass? It would be about 3X's cheaper then the Protap-Gold
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Old 01-24-2010, 01:27 AM #4
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Default Re: Question machining Cu

WD-40 does work for aluminum and brass. Try it out on a scrap and see if it will work OK for you.
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Old 01-24-2010, 02:03 AM #5
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Default Re: Question machining Cu

Thanks guys!
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Old 01-24-2010, 02:10 AM #6
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Default Re: Question machining Cu

Good old Kerosene often works for aluminum. Likely would work for Cu but the WD40 was easier to grab.

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Old 01-24-2010, 02:50 PM #7
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Default Re: Question machining Cu

Quote:
Originally Posted by Greenmechanic View Post
Mike,
I don't [have any tips for non ferrous metals] either. Never had the need for them. I work mostly with Al. or Alpha Brass or Brass/Ni alloy.
Never had the need? I'm pretty sure aluminum, brass, and nickel are all non ferrous metals - sounds like a need to me.
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Old 01-24-2010, 03:01 PM #8
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Default Re: Question machining Cu

Hi all,
Just got a quick(semi-related)@ question:
I've been boring out a tube similar to a Kryton, in Aluminium, and the boring tool's left a rough finish and vibrates slightly when being used. Would using oil help much or is this just an inherent issue when boring quite deep into a material? The lathe's ancient and the tool has been re-shaped and re-welded after snapping several times, which probably doesn't help...
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Old 01-24-2010, 05:18 PM #9
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Default Re: Question machining Cu

The only 2 times i worked with Cu, one on a lathe and one on a rectification machine, it was a damn hell of pain you-know-where (sorry) ..... i had to do it cause the "real" lathe worker was at home, and was needing an emergency part for a CNC, but, hell, that was the first and last time i made it for them ..... on the lathe, needed to go in decimals for each pass (and i mangled the first piece too ), and on the rectification machine, in centesimals, and both the machines was working in constant emulsion flux ..... it's a damn bitch to work, if i can say so

Anyway, about the tools, i never used carbide or widia ones ..... i took old hardened tools (HSS steel) for aluminium, and repassed the cutting angles ..... you need to increase the angles, for copper, cause "normal" tools have cutting angles usually planned for more hard (and less "sticky") metals ..... like, as example, if the cutting angle for iron is 8 or 10 degrees, you need to almost double it, for copper ..... and the same for that what is called "clearance" part (the part under the cutting edge ..... better do a draw, my English is not so good )



Also, the tools must be kept more "short" as possible, for avoid oscillations, and the speed of the piece also must be low ..... as i said, a damn PITA


Edit: i just remembered, the oil that we was using was called "aquamet 205", i think from agip, but i don't know if is sold in small quantities ..... it was an oil specifically planned for become emulsionate with water, making a fluid that was looking like milk, and was used in the continuous cooling systems for CNC and lathes / mills ..... maybe there's something similar for small works, but i really don't know, sorry.
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Old 01-25-2010, 05:10 AM #10
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Default Re: Question machining Cu

Quote:
Never had the need? I'm pretty sure aluminum, brass, and nickel are all non ferrous metals - sounds like a need to me.
Let me rephrase that. I have never had any problems working with standard tools before turning this Cu.
As HIMNL9 states cutting back the relief angle has worked on all projects, before now.
But the largest peice of Cu I have machined was a 1-1/2 X 3/4" heatsink.
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Old 01-25-2010, 05:43 AM #11
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Default Re: Question machining Cu

Copper is a real bear to machine, just when you think you have it figured out the damn stuff up and grabbes your cutting bit and jerkes it's self right out of the jaws of the chuck , falls down on the ways and just lays there and laughs at you.......hahaha

and at other times it's the most beutiful metel to machine, depending on how fast you are machining and how hot it is getting you can get a rainbow of colors in the metel, it can be quit stunning at times !

And it's the best for making direct press heat sinks from !


Here's my tip for machining copper or any other metel for that fact, I use only one lubricant for cutting on the lathe and it can be seen in this picture.

That's right it's spray chain lube from Polaris now don't tell anyone it's our secret !

Happy machining

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Old 01-25-2010, 08:55 AM #12
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Default Re: Question machining Cu

Quote:
Originally Posted by Flaminpyro View Post
That's right it's spray chain lube from Polaris now don't tell anyone it's our secret !
We all know Flamin's copper secret now!

Thanks for this advice, it's always nice to know for the future.
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