Actually it is driven by woodworking.
I want to build structures with angle iron, which is mild steel.
I have a small stationary metal cuttering band saw that cuts rather well, better than a chop saw.
I need to drill or bore quite a few 0.25 to 0.625 inch diameter holes onto angle iron.
I have a 16 inch dress press. Can I do a good job? Mostly 0.125 inch thick, sometimes 0.25 inch. I suppose to drill small holes on angle iron, I need to use the highest speed, 3800 rpm.
What drill bit should I use? I think I need very high quality HSS at least. Do I need to get a drill bit resharpener and reshapen the bit after every couple of cuts? Do I need special metal cutting oil?
Edited 2/23/2006 1:16 am ET by woodenfish3
Replies
Your drill press will work. First warning: Clamp the metal to the table, don't try to hold it by hand.
There are drill speed charts available for size and materials. Use coolant and go to the slow speed end of the range. Especially for the .625 holes otherwise they will wear (burn out) fast.
Pause the feed pressure or back out slightly to keep from making long curls of swarf.
HSS bits are fine and if of good quality should drill dozens (at least) of holes if you have the correct speed, feed, and use coolant.
Check out a basic metalworking/machining book from a library or see if any of the companies selling metal working machines also sell books. (Maybe Grizzly.) That will give you the answers to every thing you asked and more.
Titanium nitride drill bits or industrial bits would be best if you're drilling a lot of holes and cutting oil is definitely recommended. You don't need to use the highest speed- drills work by chipping out the material so watch your feed rate and don't rush it. Heat is what kills cutting tools and once they overheat, they're useless unless you're willing to grind the tip or edge back to correctly tempered material.
Learning metal work is a wonderful addition to your woodworking skills. Great for repairs, jigs and hardware. It's a slippery slope for some.
HSS bits are fine. You don't need the highest quality for what you are doing.
http://www.chaski.org/homemachinist/
There's some good basic metal working books around. Go to the library and tale a look around and read all those first. Some basic trade school stuff is a good start.
I'd recommend an oxy/acetylene torch for silver brazing, basic welding, bending, etc. A lot of guys will say go MIG but I foind the torch more useful than the MIG over all. I do have a small MIG but I really want a TIG. That's the ultimate but I would never get rid of my torch. Plus if you can weld with a torch you can learn to TIG a lot easier.
Your bandsaw will be fine. I assume it's one of those horizontal/vertical bandsaws. That's the best entry level saw you could have. You can cut to length and some simple scroll work. There is a handheld saw that will cut steel and the next level up is a cold saw which is entirely different and far more expensive.
http://www.makita.com/menu.php?pg=product_det&tag=4131
Wood....,
I think in time you will find that blending other fields with woodworking can enhance your results...
Using Copper Foil/Leaded Glass in doors and sides of cabinets and clocks with beveled glass...
Blending the field of electrical wiring to help the cost of lights, wall plugs and 220v power tools....
Also, here is a link to show you how blending metalworking with woodworking allowed me to have a mobil workbench that has the flexiblility in storage, clamping, and stability. Let me know what you think. Bill
http://www.millerwelds.com/education/projects/mboard/showthread.php?t=118
http://www.mcmaster.com
Pages 1526 and 3433 have perforated square tubes you can make things out of. They also carry some of the 80/20 structural extrusion. Great stuff. http://www.8020.net
To drill accurately lay out your holes and then use a centre punch to keep your bit from wandering. Use a cutting oil. my machinist book recommends a soluble(water-based) oil.
For your drill bit speed use the following formula and get as close as your press will allow. RPM=CSx12/3.1415xD. If your RPM is too high you risk overheating your bits and ruining them.
CS= the recommended cutting speed in feet per minute
D= the diametre of the drill being used
the following table will help with the cutting speeds.
1/4"=610, 5/16=490, 3/8=405, 7/16=350, 1/2=305, 5/8=245, 3/4=205, 7/8=175
For pilot holes the thickness should be slightly larger than the web of the next larger drill bit. This will do a couple of things. It will make your holes more accurate and help your bits last longer. If you have them, use split point bits with your metal. They will cut better.
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