Dear Aluminum Man,

I’m a big fan.  Saw you at EASTEC.  Hey, what’s the best way to machine an Audio Plate (see photo) from 1/8” 6061 T6 Aluminum?

Ted, Machinist

Dear Ted,

Very good question to which I have a very good answer.  First, get a Datron OmniRaptor.  From there, the rest is easy.  It goes like this:

Tool 1: 30 degree x .012” tip engraving tool at 40,000 rpm – 30 i.p.m.

Tool 2: .120” dia. high speed end mill at 45,000 rpm – 200 i.p.m.

Probing: 30 seconds
Engraving time: 1:50 minutes
Tool change: 23 seconds
Milling time: 1:29 minutes
Bevel: 55 seconds

The production of these plates could be machined out of a large size sheet, minimizing operator interfacing. Multiple panels could be milled, drilled, beveled and engraved in one complete step. On this particular sample, the countersunk holes can be done with the “countersink” command in the Datron software. This is an optional feature that can be used in lieu of a countersunk bit. The Datron software also offers many canned cycles for features required by the panel industry such as, “D” Holes, drilling and tapping, pockets and rectangles with notches in the corners for square part incising.

Then you’ll be a Datron Warrior like Aluminum Man!

AL

Dear Aluminum Man,

I’m your biggest fan!  I was just wondering how you feel about the other Superheroes … I mean, is it competition?

Sally N.
Boston, MA

Dear Sally,

Thanks for your email.  No, it’s not competition because where aluminum is concerned, I’m da man.  It’s more like a fraternity.  Bruce … ah, I mean Bat Man and I hang out from time to time.  Especially when he needs to get away from Boy Wonder … and can you blame him … what a wuss!

Dear Aluminum Man,

It’s me Sally again.  Speaking of Boy Wonder, have you ever considered a sidekick?

Dear Sally,

Aluminum Man works alone.  I could go for a female counterpart though … she could be ALUMINA.  Although, I’ve got the aluminum thing covered.  Incidentally Sally, what are your measurements?  I mean … maybe the ALUMINA suit will fit.

Oh Aluminum Man … my man of metal, I thought you’d never ask.  I’m 5’2” and 223 lbs. and I’d like a pink cape to match my rosy cheeks.

Love, Sally XOXO

Sally,

So sorry, but Manfred (my butler) told me the suit’s already been tailored for someone a little more petite. I hope we can still be friends?

AL

Aluminum Man,

Friends?  I thought we were partners … like life partners?  I can’t live without you.

You sound like a bunny-boiler and you're starting to scare me.  I’m having my Web Master revoke your membership.  And please stop calling my cell phone … how did you get that anyway?

AL