Cutting Aluminum Knife Scales with a Shapeoko 3 CNC Router

This documents my first go at machining aluminum on the Shapeoko 3 xxl with a PWNCNC 1.5kw water-cooled spindle. It's not meant to be a how-to as there is plenty of room for improvement in both heat mitigation and workpiece holding.
Chatter and vibration, heat buildup, and incorrect toolpath settings were some issues I ran into. However, at the end of the day, it turned out decent so I'll consider it a moderate success.
As always, if you have any questions or suggestions, feel free to drop a comment below. And, make sure to subscribe so you're the first to see the next project come to life.

[@chrishayes5755]

for 1/8" try this: 0 flute, 10k RPM, 65 IPM, 0.005 DOC for 1/4" try this: 0 flute, 10k RPM, 65 IPM, 0.01 DOC ramp up the IPM and test up to 80+ instead of going with a more aggressive DOC. S3 isn't very rigid from my experience it doesn't like taking large DOC, especially on a 1/8" end mill.

[@spacegoonstudios]

I'll have to give that a try next time. I think the key is the 0 flute.

[@jasonhodgins1685]

Take a look at O-flute end mills (single flute) for cutting aluminum. Better chip load control with router cnc, combo that with your VFD spindle, you could do really well. I use O-flutes (1/8", 1/4", 2.5mm) with my 1-1/2hp DeWalt router and have been successful with 6061 up to 3/8 thick so far running contours, adaptive, and bores.

[@spacegoonstudios]

I've seen mention of 0-flute. I'll have to give one a try the next time I get my hangs on a slab of aluminum. I think my problem was that when I told Fusion to ramp... it did the whole pass ramping instead of entering with a ramp to 0.010" and staying at that depth. So by the time I finished a contour pass, it was probably trying to take a 60 thou chip.

[@rubenreynaga1572]

I agree o flute is the way to go this come from me melting aluminum and coated my bit with molten aluminum.

[@wout_vanhims]

I thoughts its only me who ‘s sweating while whatching the cnc doing it thing after hitting start button

[@spacegoonstudios]

I'm a toolmaker by trade. Doesn't matter if it's a mill, lathe, CNC, or laser... I'm on edge the whole time. I guess it keeps you safe though!

[@shoreyponto]

how is it machining g10 with this cnc?

[@spacegoonstudios]

It's very doable. Lots of trial and error involved though, as far as feeds and speeds are concerned. And, it is very hard on the tools so you have to replace them fairly often. Whatever you get into, just make sure your dust collection is on point. You don't want to breathe G10.