Drilling through aluminum is a pain in the butt. If you don’t do it right, you’ll ruin the material or ruin your tool. Even worse, you’ll end up with a rough cut or you’ll overheat it. However, using the right hole saw and the right method can make the job much easier and safe. Here’s how to use a hole saw on aluminum the right way.
Yes, you can use a hole saw on aluminum, but you must use a bi-metal or carbide-tipped hole saw at a slow speed. Additionally, make sure to lubricate with oil or wax to reduce heat and keep the teeth from clogging up as you’re drilling.
To get a nice, smooth cut, keep reading for more detailed instructions and some tips for using a hole saw on aluminum.
What kind of saw do you use to cut aluminum?
Circular saws are great for cutting aluminum because they don’t create as much heat. However, if you need to make a rounded hole, you’ll want to use a bi-metal or carbide-tipped hole saw. These hole saws are made to work with non-ferrous metals like aluminum and will give you a much smoother cut than a standard saw.
Can you drill holes in aluminum?
Yes, you can use a normal high-speed steel (HSS) drill bit for drilling aluminum. However, I recommend using a cobalt drill bit. These bits quickly dissipate heat, which keeps the aluminum from melting and sticking to the drill bit.
Can I use a wood hole saw on metal?
Now, you can use a bi-metal hole saw designed for wood on metals like aluminum, but I don’t recommend it. It will work, but it’s not the best way to do it. Using a dedicated metal hole saw will be faster and give you a cleaner finish. Bi-metal hole saws are slower, but they’re more versatile because they can cut through both wood and non-ferrous metals.
How do I prepare the aluminum surface for drilling?
Before you use a hole saw, you need to prepare your aluminum:
- Clamp down the aluminum: This will keep it from moving or slipping as you drill.
- Mark your hole: Use a marker to make sure you get the hole where you want it.
- Lubricate the surface: Apply cutting oil, wax, or even WD-40 to reduce friction and keep it from getting too hot.
What speed should I use when drilling aluminum with a hole saw?
One of the biggest mistakes people make when drilling aluminum is they set their drill to run at a high speed. You want to set your drill to run at a low speed (around 200-500 RPM). This will help prevent heat buildup, which can cause the teeth on the hole saw to clog up and the aluminum shavings to stick.
What is the best lubricant for cutting aluminum?
You definitely don’t want to cut aluminum dry. You’ll want to use a special cutting oil, wax, or even WD-40. These lubricants help dissipate heat and keep the little metal particles from clogging up the teeth on your hole saw.
Summary
You can definitely use a hole saw on aluminum if you use the right hole saw and use it the right way. A bi-metal or carbide-tipped hole saw at low speeds with plenty of lubrication will allow you to cut through aluminum like butter. Make sure you follow the proper steps to prepare your aluminum and avoid the mistakes people commonly make when cutting aluminum.
