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24th Jun 2021, 11:14 PM #1New Member
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Need advice on cutting grooves in aluminum rod
Hey, guys. I was wondering if it is possible to effectively and inexpensively cut grooves for O-Rings in aluminum rod without a lathe? I have a small project where I want to make a custom hydraulic piston, but can't justify the expense of a lathe. It seems to me that aluminum is soft enough that there should me some kind of tool similar to a pipe cutting tool that could cut grooves, but googling around has gotten me nowhere. Any ideas would be appreciated.
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24th Jun 2021, 11:26 PM #2Novice
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- Sep 2019
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- Nagambie vic
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Depending on the size of your work piece but could you hold it in a pedestal drill to turn it and use a cutting edge to cut the groove? I’m just trying to think outside of the box I’m obviously not trained in engineering or machining but have seen lots of improvisation after working in agriculture for the last 15 years
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24th Jun 2021, 11:30 PM #3China
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A appropriately size round file and a vice would do it with some judicious care.
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25th Jun 2021, 06:02 AM #4New Member
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25th Jun 2021, 06:03 AM #5New Member
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25th Jun 2021, 09:21 AM #6Most Valued Member
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If you dont have the skills or the machinery to do this then you need to find a machinist local to you, at least get a quote.....
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25th Jun 2021, 10:03 AM #7Most Valued Member
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- Nov 2007
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Could you improvise something with a Dremel? Like in the picture, only with a hole for the aluminium rod to pass through at 90 degrees to the Dremel bit.
Chris
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25th Jun 2021, 10:39 AM #8Mechanical Butcher
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- Oct 2004
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Would it suit you to buy a used lathe, do your job and resell it?
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25th Jun 2021, 07:20 PM #9Senior Member
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- Sep 2009
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- Newcastle
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O rings require a properly sized groove with an appropriate finish. If you are doing this for a hydraulic piston then I don't think you can do it without a lathe (or using a mill as a lathe)
If it was purely decorative, then sure whatever.
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26th Jun 2021, 06:41 AM #10New Member
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26th Jun 2021, 06:44 AM #11New Member
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26th Jun 2021, 06:48 AM #12New Member
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I had considered something like this, but my concern ends up being how to get a respectably even groove all the way around when the rod itself is not turning. The jig would help with alignment, but then you have to think about minutely turning the rod over and over again. It may end up being the best option, but want to see what other ideas come up first. Thanks for weighing in.
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26th Jun 2021, 06:53 AM #13New Member
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26th Jun 2021, 09:26 AM #14
After cutting the groove it could be polished by using abrasive cord.
Much easier to get someone with a lathe to do it for you.
H.Jimcracks for the rich and/or wealthy. (aka GKB '88)
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26th Jun 2021, 09:58 AM #15Mechanical Butcher
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- Oct 2004
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- Southern Highlands NSW
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I don't think an abrasive cord could be used, because the O-ring groove should be something like rectangular in section, not round.
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