Rounding Corners on Aluminium Plate

[Jigantor]

I don't suggest anyone try this because it could be dangerous.
I have tried all sorts of ways to round the corners on the plates I use.
Band saw, linishing and a press with a die but it never gets a perfect round corner and it always needs linishing. Today I decided to try using a router.
I have a router table and purchased a cheap router bit to use.
Clamped the 6mm or 1/4" thick plate between some pine studs to cut down the chatter.
Here is the result.
I then tried rounding the corners of a 100mm or 4" diameter tube that had been 1/3rded.
Here is the result of that test.

Ji

[chewinggum]

That's a good idea. I have used a router to round the edges of plates for years, but I never thought about standing one up and doing the corners.
Nice.
CG

[aametalmaster]

Must be a down under word 1/3rded
Great idea. Plus the wood prob keeps some vibration down...Bob

[Jigantor]

The wood also helps keep the job in line with the fence when passing the gap in the fence around the cutting bit.

Ji

[Helios]

It makes sense, since they say that the cut speeds on bandsaws, etc., are similar for wood and aluminum.

Thanks for posting up.

[Jigantor]

This is not as precise as a mill but have you ever set up a mill to round corners off a plate. You require an indexing head worth $500.00 and the time required will make you think weather this part is worth it. To set the fence on the router table took a few minutes and the clamping similar. The actual run time through the router was lets say 3 seconds then I just had to unclamp and reclamp on the next corner. Total time from start to finish 10 minutes.
It was so easy I bought a larger diameter bit and recornered them to get just what I was looking for.

Ji