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Different way to cope a part on a vertical


Oct 20, 2005
Wilmington DE USA
I’ve made a part for a customer for 10+ years

6 a year not a high volume, part is 2 x 3 x 1.2 aluminum

1st op /detail is a 2.5” radius so the part will saddle a 5” tube to be welded in place

Early runs I used a ½” ball mill with a hand written program cutting along X axis

Moving in Y dropping in Z to give a quazi cope

Appearance/finish wasn’t to important as the cope was used just to clock to the tube.

2nd method was a boring bar set to 2.5 radius in a boring head

Successive Z cuts , moving in X towards blank until needed cope was complete, but still leaving flats to support other side ops.

Although this created a much better part, setting the bar was a pain

What I do now is use a HSS 5” diam 60tooth 1/8” slitting saw I picked up on EEbay used

Cutting 0.020 with each X cut, feeding 18ipm in Z @1600rpm

Very good finish, easy setup

I’m sure many will look and say, yeah do it all the time, if its new to someone my sharing was worth the post


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Hot Rolled
Dec 16, 2011
I wouldn't have thought to use a slotting cutter like that. I'm surprised it has the clearance to cut without rubbing and gumming up. It's cool that it works.


Oct 20, 2005
Wilmington DE USA
In the 2nd pic you can see the "peel" created during the cut
there are chips formed, and full coolant stream adjusted at front of cut
The X amount, feed and rpm was is the sweet spot for this particular piece
To slow and the cutter sings
to fast and chomp chomp chomp
A thinner blade or one with more teeth may flex and break
Surely not for high volume, but with the process proven it only take about an hour from setup till 6 pieces done
Burr is removed with a finger
Customer is happier evan though a hatchet chopped trough would accomplish the same