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How to Achieve Optimal Results

To ensure you always achieve the desired and best results when working with aluminum—whether cutting, grinding, or polishing—the following factors must be taken into account:

  • Use cutting and grinding discs with special bonds that prevent clogging of the disc.
  • Use flap discs with a special, suitable coating.

Hazards Associated with Aluminum Processing

Whenever you perform cutting, grinding, or polishing on aluminum, aluminum dust is produced. This dust is highly flammable and reacts with moisture to form highly flammable gases. There is therefore a risk of a grinding dust explosion.

In addition, inhaling aluminum dust can lead to aluminosis (also known as aluminum dust lung). If aluminum dust enters the brain via the bloodstream, there is also a risk of Alzheimer’s disease.

Cutting or trimming aluminum

  • The special bonding of the extra-thin cutting disc prevents it from clogging. These discs deliver exceptional cutting performance even on low-power machines.
  • When cutting aluminum with an electric angle grinder, you can reduce dust generation by half by using an extra-thin aluminum cutting disc.
  • Clean the angle grinder after each operation. Aluminum dust is very fine and can accumulate in the angle grinder despite the dust extraction system, potentially damaging it. Pneumatic angle grinders are less susceptible to dust during use.
Cutting aluminum – with the RHODIUS XT24
Chamfering aluminum - With the RHODIUS RS24

Chamfering aluminum – welding preparation

  • Use a grinding disc, flap wheel, or fibre disc here; their special bond prevents clogging of the wheel, ensuring efficient and continuous grinding.
  • The discs marked with the ALU symbol achieve high material removal rates combined with a cool grinding process. This means: less tarnish colours. They are equally well suited for machining bronze, brass, non-ferrous metals, and aluminum-magnesium alloys.

Deburring aluminum – Pre- and rework of welding seams with a milling cutter

  • When machining aluminum, you should choose special tungsten carbide burrs with fewer but deeper-cut teeth, a positive rake angle, and a ground facet.
  • If you need to machine aluminum, the optimal spindle speed is 700–900 m/min.
HF B carbide end mill with Z ALU flutes
Aluminum Polishing – Polishing Paste for High-Gloss Polishing of All Materials

Polishing aluminum

  • For an optimal surface finish, the workpiece should no longer have any deep scratches or inclusions. Ideally, the aluminum should have been machined with a grit size of 60 or higher prior to polishing.
  • The last fine scratches can then be removed using combination tools made of non-woven discs and abrasive cloth. Work at reduced speeds here and in the following steps.
  • For further leveling of the surfaces, tools made of compact fleece are recommended.
  • Pre-polishing is first performed using felt of high hardness or hard polishing rings made of cloth fleece and the appropriate paste.
  • Use tools made of softer felt or soft polishing rings made of cloth fleece, along with the appropriate paste, to achieve the final mirror finish.
  • Use a separate tool for both pre-polishing and high-gloss polishing.

The right products for these applications