Cutting metal

[tp4tissue]

Using a drill press with a dremel bit attached. to cut aluminum. 

(yes) I am wearing paintball mask.

Do I use high rpm or low rpm..

[Photoelectric]

Start low and if you have variable RPM settings, go higher to whatever feels right.  I used higher RPM for steel computer cases, but I think aluminum is soft enough for slower RPM.  Also make a groove on the surface with your dremel saw along the cutting line first--it will make guiding the circular saw much easier when you actually cut.

[SpAmRaY]

I would add some decent gloves along with the mask.

[Photoelectric]

I would add some decent gloves along with the mask.

Oh yeah, definitely.  I use cheap transparent plastic goggle/glasses from HomeDepot.   Sparks will fly all over the place, and at least with steel, there's lots of metal dust and some larger pieces.

[eth0s]

Using a little machine oil at the cutting point can cut down on sparks and metal bits flying around, also keeps surface cooler.  But it can make a greasy mess if you're not careful.

[swill]

I was planning to try with a grinder. I don't have a drill press. Anyone do this with a grinder?  Hints?

[tipo33]

I have cut into a Lian-Li with a Dremmel, it's easy.  It certainly depends on the thickness and quality of the aluminium.

[tp4tissue]

I would add some decent gloves along with the mask.

Oh yeah, definitely.  I use cheap transparent plastic goggle/glasses from HomeDepot.   Sparks will fly all over the place, and at least with steel, there's lots of metal dust and some larger pieces.

Um...

I'm pretty sure that Drill press guidelines specifically says DO NOT WEAR GLOVES..lol

[tp4tissue]

I was planning to try with a grinder. I don't have a drill press. Anyone do this with a grinder?  Hints?

Grinder is good.. but not for small parts..

Grinder can cut something bigger than itself..

I'm using a drill press so that I can hold the small part, while passing it through the cutter.

[YoungMichael88]

I would add some decent gloves along with the mask.

Oh yeah, definitely.  I use cheap transparent plastic goggle/glasses from HomeDepot.   Sparks will fly all over the place, and at least with steel, there's lots of metal dust and some larger pieces.

Um...

I'm pretty sure that Drill press guidelines specifically says DO NOT WEAR GLOVES..lol

I would avoid loose fitting gloves for sure. Mechanics gloves should be fine as long as you're really careful.

[kolonelkadat]

no gloves.

use alumatap http://www.amazon.com/Ounce-AlumTap-Cutting-Winbro-Each/dp/B002R84X6U

RPM will depend on cutter radius and material.

[TheSoulhunter]

If your setup is stable and you use TC bits you won't need cooling/lubrication or lowered RPM for aluminium,
just keep an eye on the feed rate as TC tends to break easily when applying too much pressure.
If you use HSS bits, lower the RPM and apply cooling/lubrication...

[TheSoulhunter]

Just noticed that part:

I'm using a drill press so that I can hold the small part, while passing it through the cutter.

Sounds like a good way to ruin your workpiece, hands or the cutting bit...
Consider mounting the workpiece into a fixture/vice to move it on the table.

[tp4tissue]

Just noticed that part:

I'm using a drill press so that I can hold the small part, while passing it through the cutter.

Sounds like a good way to ruin your workpiece, hands or the cutting bit...
Consider mounting the workpiece into a fixture/vice to move it on the table.

this is "not" precision I'm after.. I gotta make small pieces.. FAST...

[Findecanor]

Drill presses aren't made for lateral forces. What you really want is a router in some kind of stand, I.e. a mill.
Might work well for something small and fast, though.
Remember, let the machine's rotation do the work, don't force it sideways.

[tp4tissue]

Drill presses aren't made for lateral forces. What you really want is a router in some kind of stand, I.e. a mill.
Might work well for something small and fast, though.
Remember, let the machine's rotation do the work, don't force it sideways.

I shall refrain from using the force.

[Badwrench]

I would add some decent gloves along with the mask.

Oh yeah, definitely.  I use cheap transparent plastic goggle/glasses from HomeDepot.   Sparks will fly all over the place, and at least with steel, there's lots of metal dust and some larger pieces.

Um...

I'm pretty sure that Drill press guidelines specifically says DO NOT WEAR GLOVES..lol

This!  No gloves with a drill press.  Guy at work lost his middle finger (tore off at the first knuckle) when he went to brush away the metal curls at the drill point.  Circular grinder - use some leather gloves, face protection, and earplugs.  Dremmel- light gloves, safety glasses, and ear protection.  I am always surprised how loud my Dremmel is.