What Is Aluminum Machining
Aluminum machining is the process of cutting, shaping, or forming aluminum material into a desired shape or size using various machining tools and techniques. It involves removing the excess material from a workpiece by cutting, drilling, milling, turning, or other similar methods to create a finished product that meets the required specifications. Aluminum machining is widely used in the manufacturing of various products such as aircraft parts, automotive components, electronic devices, and more. The machining process requires precision, expertise, and specialized equipment to ensure that the final product is of high quality and meets the required standards.
Advantages of Aluminum Machining
High strength-to-weight ratio: Aluminum is both strong and lightweight, qualities that are critical for machined parts used in high-performance applications, such as those found in the aerospace and automotive industry.
Corrosion resistance: Aluminum is available in several grades, which vary in the degree of corrosion resistance demonstrated. In machining operations, one of the most commonly employed grades—6061—offers excellent corrosion resistance.
Electrical conductivity: Aluminum exhibits greater electrical conductivity (about 37.7 million siemens/meter at room temperature) than other commonly machined metals, such as carbon steel (7 million siemens/meter) and stainless steel (1.5 million siemens/meter). This quality makes machined aluminum parts suitable for use as electrical and electronic components.
Affordability: Compared to other machining materials (e.g., brass, titanium, and PEEK), aluminum is cheaper without significantly sacrificing performance. Additionally, its machinability results in lower production costs, while its lighter weight results in lower transportation costs.
Recyclability: Aluminum is highly recyclable, enabling manufacturers to reuse scrap material produced during machining operations and construction materials from finished products discarded at the end of their service lives.
Surface finishing and anodization potential: Aluminum readily accommodates various surface treatment and finishing processes, such as painting, tinting, and anodization. This quality allows manufacturers to improve the functional and aesthetic properties of the machined aluminum part or product.
Material: Alu5052,6061,6063,6082,6262,2011,2017,2024,7075,5083,1050 Process:CNC turning, CNC milling, Surface treament:Sandblast and anodize,Brush,Hard anodize,Polish,Chrome plated, Powder Coated, Surtec 650,Vacuum coating or PVD,etc.
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An Overview of Aluminum Machining Processes
“Machining”is an umbrella term that encompasses a range of subtractive manufacturing processes—e.g., milling, turning, drilling. There are also several types of machining technologies and techniques—e.g., CNC machining, Swiss screw machining, vertical and horizontal milling, and electrical discharge machining (EDM). Below we outline how aluminum is handled in each of these machining methods.
Computer numerical control (CNC) machining: The CNC machining process employs the use of computer software and CNC-compatible equipment to guide the movement and motion of machine tools across the surface of the workpiece. It allows for the production of highly precise and accurate aluminum CNC parts and products.
Swiss screw machining: Swiss screw machining is ideal for the production of small—but highly precise—cylindrical components made from aluminum, such as electronic or medical parts.
Vertical/horizontal milling: Milling is a machining process that utilizes rotating cutting tools to remove excess material from the workpiece. Milling equipment can feature a vertical or horizontal configuration; vertical units are ideal for small quantities of simple aluminum parts, while horizontal units are more appropriate for large quantities of complex aluminum parts.
Electronic discharge machining (EDM): EDM utilizes the electrical discharge generated between two electrodes to remove material from the workpiece. While it is generally used to process harder and more difficult-to-machine materials, it can be used on any electrically conductive material, including aluminum.
A Guide to Aluminum Machined Parts
Machining aluminum parts requires careful consideration of several factors to achieve accurate and high-quality results. Here are the general steps involved in machining aluminum parts from design till delivery:
Design and Planning:
Begin by creating or obtaining a detailed design or CAD model of the aluminum part.
Determine the dimensions, tolerances, and required surface finishes.
Consider the machining process and select appropriate cutting tools and machining techniques.
Material Selection:
Choose the right aluminum alloy based on the specific requirements of the part, such as strength, corrosion resistance, or heat conductivity.
Popular aluminum alloys for machining include 6061, 7075, and 2024.
Setup the Machining Equipment:
Ensure the machine tools, such as lathes, mills, or CNC machines, are properly set up and calibrated.
Mount the aluminum workpiece securely on the machine’s workholding device, such as a vise or fixture.
Tool Selection:
Select the appropriate cutting tools for aluminum machining. Carbide or high-speed steel (HSS) tools are commonly used.
Consider using sharp tools with high helix angles to efficiently evacuate chips and reduce heat buildup.
Cutting Parameters:
Determine the cutting speed, feed rate, and depth of cut based on the specific aluminum alloy, tooling, and machine capabilities.
Consult cutting speed charts or machining databases for recommended parameters, or conduct tests to optimize settings.
Coolant and Lubrication:
Use coolant or lubricants during the machining process to dissipate heat, prolong tool life, and improve surface finish.
Consider using water-soluble coolants or cutting fluids specifically formulated for aluminum.
Machining Operations:
Begin with roughing operations to remove excess material efficiently. This can involve facing, turning, or milling operations.
Follow up with finishing operations to achieve the desired dimensions and surface finish. These can include profiling, drilling, or threading.
Chip Control:
Pay attention to chip evacuation to prevent chip buildup and potential tool damage. Use proper chip-breaking techniques and ensure adequate chip clearance.
Quality Control:
Regularly measure and inspect the machined parts using precision measurement tools, such as calipers, micrometers, or CMMs.
Verify dimensions, tolerances, and surface finish to ensure compliance with design specifications.
Surface Finishing (Optional):
Consider post-machining surface finishing processes such as deburring, polishing, anodizing, or painting to improve aesthetics and functionality.
Cleaning and Packaging:
Thoroughly clean the machined parts to remove any cutting fluid, chips, or contaminants.
Properly package the finished aluminum parts to protect them during transportation or storage.
Reasons Aluminum Is Preferred for Aluminum Machining
Before looking at the tips to effectively machine aluminum, first, let's understand the reasons why aluminum is useful for machining.
Resistance to corrosion: Aluminum has excellent corrosion resistance, the reason is the metal doesn't contain iron. Therefore, it’s safe to machining precise parts. 6061 is a popular grade for machining, it has resistance to oxidation and chemical damage.
Some aluminum alloys have copper in them which are not corrosion-resistant, not suitable for machining. Therefore, one needs to analyze the chemical properties before choosing aluminum.
Ideal strength to weight ratio: Aluminum as a material provides the optimal strength to weight ratio which is necessary for various industrial applications. Aluminum brings strength but is also a lightweight material. Aluminum alloys 6061 and 7075 are some examples displaying strength to weight ratios.
7075 grade works well with the automotive and aerospace industry whereas 6061 grade is suitable for general uses.
Ease of machining: The machine shop owners look for one thing in a material, which is suitability for machining. Aluminum is easier to machine than other metals like steel.
With aluminum, it's easier to achieve the needed surface finish while keeping the costs in check. Aluminum offers a short machining time making it more beneficial for machine shop owners to manufacture the product within deadlines.
Anodization: Anodization is one more benefit of aluminum which is ideal for window panes. Aluminum gets used in applications where aesthetics matters a lot. The aluminum is anodized for a fine surface finishing, it helps to give aluminum the coloured outlooks while maintaining corrosion wear and tear.
What are the Different Types and Applications of Aluminum Machining Parts
There are many different types of aluminum machining parts, each with its own unique properties and applications. Some of the most common types of aluminum machining parts include:
Structural parts
These parts are used to support other components or assemblies. They are typically made from high-strength aluminum alloys and are often used in the aerospace, automotive, and construction industries.
Machined components
These parts are used in a variety of machines and appliances. They are typically made from high-precision aluminum alloys and are often used in the medical, electronics, and manufacturing industries.
Precision parts
These parts are used in applications where high accuracy and precision are required. They are typically made from high-grade aluminum alloys and are often used in the aerospace, medical, and defense industries.
Formed parts
These parts are made by shaping aluminum sheet metal or plate. They are typically used in a variety of applications, such as automotive, appliance, and furniture manufacturing.
Cast parts
These parts are made by pouring molten aluminum into a mold. They are typically used in applications where high strength and durability are required.
Extruded parts
These parts are made by forcing molten aluminum through a die. They are typically used in applications where long, straight sections are required.
Tips to Keep in Mind While Aluminum Machining
As a machinist you are the decision-maker of the company, you are done with the first step by choosing aluminum as your material. The second step is to remove any issues that you can face during the manufacturing of aluminum machined parts.
So, here are the brief tips to take care of before aluminum machining.
Thermal considerations
Heat harms the machined part. The heat must be spread to a larger area to reduce the impact and avoid thermal deformations.
The temperature increases with the speed of the machining process. Use symmetrical machining to overcome this issue. The surface area of the workpiece in contact with the cutter should be larger in symmetrical cases.
Right tool selection
Tooling selection is a vital thing to understand before moving with the manufacturing process. A wrong tool selection for custom aluminum machining can cause adhesion.
Therefore, it's necessary to select carbide cutting tools when doing aluminum machining. Aluminum gets sticky which leads to build-up at the edge of the cutting tool.
Tools with a high concentration of cobalt are not preferred for aluminum machining as with high temperatures, the aluminum reacts differently with cobalt. Now, aluminum machining carbide tools are the ideal fit.
Manufacture according to optimal cutting parameters
Precision machining requires the machinists to input the programming to get the optimal result of the machined parts. Professional CNC machinists can help to overcome cutting problems like back cutting, which happens because of uneven tool wear.
CNC high-speed milling is the way to solve the issue and improves efficiency. One needs to focus on cutting tool parameters such as rear angle, front angle, helix angle and more.
Working on thin-walled aluminum parts
Machining thin-walled aluminum parts is a difficult task in and of itself. The workpiece must be clamped during machining. Clamping thin-walled aluminum parts, on the other hand, may cause deformations. In this case, machinists use a two-stage compression method. It requires the machinists to have proper experience and capability to handle the custom machining of thin aluminum parts.
Keep chip management in mind
Aluminum's ductility causes long, unbroken chips to form around a tool. It leads to tool breakage, heat buildup and more. Keep an eye out for chips when cutting aluminum. Chip removal should be incorporated into your process, whether it’s through a fixed air blast system, high coolant flow rates, or in chip conveyors.
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