OT: Cutting a hole in 1.5mm/ 0.06 inch thick steel, any get-by technique?

[Michael A. Terrell]

The cutting oil is a good idea, essential even. That said, I don't
think you want to be grinding on a saw blade of any kind. Aside from
the difficulty in obtaining any kind of precision, the heat generated
will degrade the steel.

Has anybody used those hole cutters which are a pilot bit with a single
carbide 'knife' on the end of an adjustable arm? I've seen--but not
used--them.

http://www.cleavelandtoolstore.com/images/fc53_lg.jpg

A fly cutter? I have cut some very clean holes with them, chucked
into a 3/8" variable speed drill. the trick is to cut about half way
through, then finish from the other side. A drill press is easier, and
safer to use with this type of tool. I cut a lot of holes for panel
meters with one, about 30 years ago. is a
good place to ask, but beware, they don't pull any punches, and tell
people what they think.


--
Service to my country? Been there, Done that, and I've got my DD214 to
prove it.
Member of DAV #85.

Michael A. Terrell
Central Florida

 

[N Cook]

No proper mechanical engineer was around.
Took about half an hour to cut a very clean hole.
Used a 72mm downlighting holesaw, working from one side only.
http://home.graffiti.net/diverse:graffiti.net/cutter.jpg
mm graph paper behind
42 teeth on the cutter so decided on keeping every 6th tooth and grinding
back the rest. Black felt tip line marks one of the untouched teeth.
Hole is quite round and very clean, no waveyness nicks etc and varying only
between 71.9 and 72.2mm in diameter.
Left image is the approach side and right image is the breakout side.
The grey smudgey line on the left image is my felt tip mark to show where to
put the plasticene bund, not anything due to the cutter. I carried on
cutting until broken through 3/4 around and then hand snapped the remainder.
The breakthrough side had a thin and narrow swarf ribbon perpendicular to
the sheet which cut away easily with a stout knife, the only finishing I did
before taking the pics, other than washing off the cutting oil.
As a standard hand drill in a drill press, not geared down, I had to stab at
it, ie spin up / drop+cut / release/ spin up ...