This article describes the methods, tools, environments, and challenges related to aluminum cnc machining and its typical alloys. It focuses on aluminum properties, the usual alloys used in machining, and their applications in different fields.
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In particular, aluminum is a second metal used more frequently than other materials apart from steel. The high demand for aluminum is because of its due tong characteristics, and machining and ease of machiningtal, aluminum is relatively low dense, malleable, easily formed, nonmagnetic, lustrous, and silvery-white. Aluminum is usually alloyed with elements like manganese, copper, and magnesium with improved characteristics.
Typically, custom CNC aluminum features the following benefits.
Strength-to-Weight Ratio
Aluminum is about one-third the density of steel. Even with low density, it features high tensile strength, making it ideal for automobile and aircraft industries.
Machinability
Aluminum alloys are easy to machine compared to other types of metals. They are also machined fast and with minimum power supply. Because they are relatively soft hence reducing the costs of machining and power. This machining ability avoids deformation and guarantees precise tolerances.
Corrosion Resistance
Aluminum has a natural corrosion resistance in different conditions. Anodizing further enhances this resistance. The majority of the used aluminum grades possess high protection against corrosion and, thus can be used in various applications.
Electrical Conductivity
Aluminum, the purest form, has a conductivity of electric current of 37.7 x 106 S/m at 20 degree Celsius. Aluminum alloys have low conductivity. However, they remain suitable for electrical applications when high conductivity is not critical.
Custom Finishing
Aluminum machined components can be anodized, powder coated, or painted to suit project requirements.
Recyclability
Aluminum is recognized as a recyclable material as the process costs low energy and is cheap. This property not only minimizes wastage but also assists manufacturers in making an effort to regain their costs while encouraging sustainable practices.
A table with key features and specific applications for various aluminum grades used in aluminum cnc machining is given below:
Series Alloying Element Key Features Common Applications 99% or higher aluminum Excellent corrosion resistance and thermal conductivity; highly ductile. Electrical connectors, heat sinks, and chemical equipment. Copper High strength-to-weight ratio; good machinability; reduced corrosion resistance. Aircraft fuselage, aerospace components, and truck body frames. Manganese Good workability and moderate strength; excellent formability. Beverage cans, cooking utensils, and roofing sheets. Silicon Low expansion; excellent wear resistance; suitable for welding. Automotive engine components, welding wires, and die-casting molds. Magnesium Superior corrosion resistance; good weldability; and excellent fatigue strength. Marine environments (boat hulls), pressure vessels, and tankers. Magnesium & Silicon Good corrosion resistance and medium strength; versatile machining properties. Structural components, automotive chassis, and architectural applications. Zinc High strength; often used in heat-treated forms; lower corrosion resistance. Sports equipment (bicycles, baseball bats), military aircraft, and high-stress components.Choosing the appropriate tool for machining aluminum through Computer Numerical Control is a question of certain important factors.
Tool Design
Tool geometry plays an important role in machining performance. The number of flutes is a crucial design factor. Cutting tools intended for aluminum should have 2-3 flutes for efficient chip removal at high spindle speeds. An increased number of flutes can cause thinner chip valleys, and large aluminum chips can be trapped. Employ 2 flutes, when cutting forces are minimum, and chip clearance is crucial. To achieve a good compromise between the chip clearance and the tool strength, 3 flutes are recommended.
Helix Angle
Helix Angle
The helix angle is defined as an angle made between the tool centerline and a normal to the cutting edge. This angle has a significant contribution to the cutting performance. The helix angle of greater value provides great chip removal but increases the friction and heat. There’s a possibility of having the weld between the chip and tool surface during the high-speed cutting operation. While smaller helix angles may lower heat. They may also decrease chip removal effectiveness. In aluminum machining, the helix angle recommended for use when performing roughing operations is 35° to 40° while for finishing 45° is appropriate.
Clearance Angle
The clearance angle is critical to the functionality of a tool. Excessive clearance can cause the tool to dig into the workpiece. This may lead to chatter during machining. On the other hand, the angle of approach may be so small that it leads to unnecessary friction. The clearance angles should range between 6° and 10° for aluminum parts in CNC machining.
Tool Material
Carbide is more frequently used than any other material in cutting tools for aluminum machining. As aluminum is a relatively soft material, the key factor should be to have a sharp cutting edge rather than a hard one. The ability of carbide tools to maintain an edge is determined by grain size and binder ratio. These latter characteristics relate to grain size, where large grain sizes produce hard materials but small grains result in toughness and impact strength – both desirable in machining applications. The cobalt content in carbide should be controlled at 2-20%, to avoid negative interactions with aluminum at elevated temperatures.
Tool coating
Tool Coating
Tool coating also improves cutting performance. Protection for aluminum machining entails using Zirconium Nitride (ZrN), Titanium Diboride (TiB2), and diamond-like coatings.
Feeds and Speeds
Feed rate refers to the travel amount of a workpiece or a tool translated in a given revolution. This feed rate depends on the required surface finish, strength, and stiffness of the workpiece. The feed rate for the rough cut is between 0.15 to 2.03 mm/rev corresponding to the finishing cut of 0.05 to 0.15 mm/rev.
Cutting Fluid
Aluminum, although easily machined, should not be fabricated without coolant. This can lead to a built-up edge on the tool. There are soluble oil emulsions and mineral oils as the cutting fluids for aluminum machining. Do not use water with chlorine or active sulfur as this tends to stain aluminum.
Aluminum on its own is a great material, and when properly alloyed, it adds more to the material’s flexibility. Here are key industries that benefit from aluminum CNC machining.
Aerospace
Aluminum’s low density allows it to be used in critical places like landing gear and torque links which increases aircraft efficiency.
Automotive
The automotive industry is increasing its demand for aluminum. It’s used in parts like electric vehicle castings, engine parts, and body panels leading to improved fuel efficiency and performance.
Electrical
For electrical conductivity, aluminum is highly appreciated. In general, it’s used in machined aluminum parts such as PCB housing and smartphone frames for proper functionality.
Drug and Food Manufacturing
Aluminum is safe to use in the pharma and food industries because it’s a non-reactional material. It’s widely employed in food processing machinery, instruments, and medical equipment.
Consumer Electronics
In the field of consumer electronics aluminum’s heat dissipation properties make it ideal for heat sinks where it dissipates heat from different gadgets to evaluate ultimate performance.
Aluminum and steel are the most adopted in CNC Machining Service.
Let’s identify five criteria that influence the selection of the right material.
Cost
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Carbon and mild steel are cheaper than aluminum in most cases. Stainless steel is normally more expensive than the two mentioned above. The metal prices are highly sensitive to the world market requirements of the specific category. Both initial costs and the long-term durability of the material selection should also be focused.
Weight
Aluminum is lighter than steel; it is about 2 to 3 times lighter than steel. Manufacturers are inclined to use lighter materials in their products to improve performance. This trend results in replacing some steel components with aluminum counterparts.
Strength
Steel’s density makes it more durable than aluminum. Although, steel does not bend when exposed to heat or when pressure is applied to it. Still, aluminum is much more vulnerable to such defects as scratches and dents in comparison with steel.
Machinability
Aluminum is easier to machine because it is lighter than steel and normally takes less time to machine. It cools faster than steel, thus the machining cycle is short, saving time and cost. Lower coolant volumes are also required for the aluminum parts processing.
Aluminum CNC Machining is a common process of fabricating unique products due to the outstanding characteristics of aluminum alloys. These alloys build on aluminum’s inherent properties, so CNC machining is a perfect fit for a wide range of uses.
In this guide, the most popular aluminum grades used in CNC machining are explained. However, to make the best use of aluminum, it’s crucial to understand the basic process of CNC aluminum machining and choose a reliable aluminum cnc service for your project.
A CNC (Computer Numerical Control) machine runs on a computer program; it can either be for prototyping or in full item production. Aluminum is the commonly machining material, as it exhibits excellent machinability, and is thus the preferred material in the most manufacturing sector.
Aluminum as a material offers some interesting thermal and mechanical properties. Besides, the aluminum metal is relatively easy to shape, especially in drilling processes, like in CNC aluminum machining. In fact, we highly regard an aluminum alloy compared to other lightweight metals such as magnesium and titanium alloys.
The use of CNC aluminum has grown immensely, the production of CNC automotive parts and other CNC parts that are lightweight has been intense. Below are a few of the things you may not have known.
Aluminum Material: CNC Aluminum Machining
1.Aluminum Grade
2.What should be paid attention to when CNC machining Aluminum:
(1) Before processing each program, it is necessary to strictly confirm whether the tool on the program is consistent with the program;
(2) When installing the knife, make sure that the length of the tool and the selected tool holder are suitable;
(3) It is forbidden to open the door during the operation of the machine tool to avoid flying knife or workpiece;
(4) In the process of processing, if a tool collision is found, the operator must stop immediately, such as pressing the "emergency stop" button or the "reset button" or adjusting the "feed rate" to zero, etc;
(5) In the same workpiece, the tool must be kept in the same area every time to ensure the accuracy of the CNC machining center operation rules when the tool is connected;
(6) If you find that the machining allowance is too much during the machining process, you must use "single block" or "pause" to reset the X, Y, and Z values to zero, then manually mill them out and then shake them back to the "zero point" to let them go on their own run;
(7) Operators are not allowed to leave the machine tool or regularly check the operating status of the machine tool during self-operation. If they need to leave halfway, they must designate relevant personnel to check;
(8) The aluminum slag in the machine tool must be cleaned before the light knife sprays oil to prevent the aluminum slag from absorbing oil;
(9) Use air blowing as much as possible in the roughing program, and spray oil in the light knife program;
(10) After the workpiece is off the machine, it must be cleaned and deburred in time.
3.Aluminum CNC Machining Processes
We can machine aluminum using several CNC machining processes available today. Some of these processes are as follows.
CNC Turning
In CNC turning operations, the workpiece rotates, while the single-point cutting tool stays stationary along its axis. Depending on the machine, either the workpiece or the cutting tool carries outfeed motion against the other in order to achieve material removal.
CNC Milling
Milling operations are perhaps the most commonly used in CNC machining aluminum parts. These operations involve the rotation of a multi-point cutting along its axis, while the workpiece stays stationary along its own axis.
4.Industries using CNC Machining Aluminum Parts
Aerospace: due to its high strength to weight ratio, several aircraft fittings are made from machined aluminum.
Automotive: similar to the aerospace industry, several parts such as shafts and other components in the automotive industry are made from aluminum.
Electrical: having high electrical conductivities, CNC machined aluminum parts are often used as electronic components in electrical appliances.
Food/Pharmaceutical: because they do not react with most organic substances, aluminum parts play important roles in the food and pharmaceutical industries.
Sports: aluminum is often used to play sports equipment such as baseball bats and sport whistles;
Cryogenics: aluminum’s ability to retain its mechanical properties at sub-zero temperatures, makes aluminum parts desirable for cryogenic applications.
5.Axis CNC Machining
On the 5-axis machining, the CNC moves while cutting in five angles of the axes simultaneously. This machining process is fast, reliable on designing complex parts, as work is approached in multiple directions.
The 5-axis machining has been adopted widely because of the following:
The set-up is a single one, and this reduces the lead time and better the efficiency
It allows better geometry due to its ability to avoid collision with the tool holder tilting the table or the cutting tool.
Can use shorter tools that are more rigid, some with high spindle speeds rate which is achieved by reducing the load cutting tool.
Pieces don’t pass through different workstation hence errors are reduced, accuracy maintained, and quality is guaranteed.
Aluminum is a versatile material with a high level of machinability. We have a full understanding of its capabilities and machining requirements. Use our inquiry form if you require CNC Machining or contact us for any questions that you may have.
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