Practical milled edge radius on aluminum?

[CABEN]

How large of an edge radius can practically be machined on aluminum? Edge rounding cutters that I've found seem to max out at about 1&quot;. Can face cutters be swept in an arc for larger radii? The radii is to be less than a full 90 deg arc and the edge length <12&quot;.

By the way, product volume dictates that casting is not feasible.

 

[EnglishMuffin]

Probably limited only by machine/spindle stiffness - it might become a source of chatter. And of course how much you are prepared to pay for a special.

 

[Iskit4iam]

You can generate a curved surface using face cutters or end mills assuming there is no interference between the part and the noncutting edges of the tool. For concave surfaces I've used ball end mills.

English is right about spindle stiffness but you should be able to do this with standard tooling.

We needed net shape housings that would eventually be cast in aluminum. Generated them from 6x5x10 inch blocks in two setups on a CNC vertical Bridgeport. 40 CAT holders with the longest extension being 12 inches for a 1/2&quot; ball end cutter.