Oct 6,2023
A CNC machine has become the standard machine that is used worldwide in subtractive manufacturing. It is used to produce prototyping or full item production. The CNC machine is a versatile piece of machine and can cut an array of materials. Among the most commonly used materials in the CNC manufacture of complex machine parts is aluminum.
Aluminum has several properties that make it a highly suitable material in CNC milling. It is lightweight and really malleable. Moreover, it is also corrosion-resistant and does not rust, making it durable.
It is non-flammable and not vulnerable to magnetism, making it relatively unreactive and safe to use in various applications.
The use of aluminum is widespread in the manufacturing of machinery for medical, aerospace, and automotive industries. Most machine parts in these industries need to be manufactured to a strict quality standard, and mainly, these parts are produced in bulk; maintaining accuracy in CNC milling procedures like drilling and cutting is extremely crucial. In this blog post, we are going to take a detailed look at how to ensure precise CNC machining of aluminum to produce a product that matches a high-quality standard.
Work projects involving CNC machining of aluminum can vary a great deal in complexity depending on the industry. That is why it is essential to select the right quality aluminum so that it can be cut and drilled to match international standards and accurate specifications that complement the machine design.
Aluminum is available in various grades, so having knowledge about each aluminum grade is necessary to make the correct material choice. Don't worry; we are going to tell you about each aluminum grade so that you don't make a costly mistake and wind up with a sub-standard finished product.
A popular aluminum grade suitable for many conventional work projects and widely used is Aluminum 6061. It is robust, has medium to high strength, is corrosion resistant in the toughest and high moisture conditions, and is bendable and flexible without compromising quality. It is very suitable for welding. This kind of aluminum grade is utilized in 5-axis CNC machining.
For parts that are required to tolerate challenging environments with high-temperature fluctuations and impact resistance, a tougher type of aluminum is needed. Aluminum 7075 grade fits the bill perfectly due to its extraordinary fatigue strength. This grade is costlier than Aluminum 6061.
Moreover, it is not as flexible as 6061 and does not melt easily, making it unsuitable for welding. It is used to make large metal parts that are not complex shaped and require durability, like fuselages, aircraft wings, and bicycle parts. These parts need to be rust-resistant and long-lasting, and this type of aluminum is perfect.
The most commonly used aluminum grade in the military and aerospace sector is Aluminum 2024. This particular type of grade has high strength and weariness resistance but, on the downside, is not great for welding.
Although aluminum is one of the most popularly used materials, maintaining precision during CNC milling of aluminum is a challenge due to its properties. Aluminum alloys are soft and have a high thermal expansion.
This thermal expansion results in the metal losing its shape when it is machined into a thin sheet. However, if correct machining techniques are followed, then these properties will not pose a problem, and the finished product will have the required shape and specifications. Let us take a look at these various techniques.
This machining technique emphasizes avoiding heat concentration in a particular surface area of the aluminum metal during the machining. The machining is executed in such a way that the heat is distributed evenly. This reduces the rate of thermal deformation.
If multiple cavities are present on an aluminum alloy plate, there is a risk of one of the cavity walls getting easily deformed due to uneven force distribution. To prevent this from happening, it is advisable to address all the cavities simultaneously during the processing.
The operator should strive to reduce the number of cuts applied to a particular metal piece, as excessive cutting can lead to deformation. The best way to achieve this is to reduce the cutting force and increase the speed of the cutting.
A milling cutter can distort the surface of a cavity due to cutting heat if applied improperly. To avoid this issue, it is best practice to drill with a bigger tool than a milling cutter. After this, apply the milling cutter and mill to the workpiece.
Although the above machining techniques are really useful when you are working with three or 4-axis CNC machines, if you want to avoid the hassle of following these precautions and techniques, it is better to invest in a 5-axis CNC machine. Although this machine is expensive, it is worth the price and makes CNC machine operation a piece of cake.
The finished product will match the specifications you want without much interference on your part. The 5-axis CNC machine moves along five angles, making it suitable for forging complex parts. Several features make the 5-axis CNC machine exceptional.
The machine setup is single and quick. This reduces the product cycle time.
Allows for precise cutting as the tool holder has less risk of clashing with the tilting table or cutting tool, which means less chance for error.
It can utilize shorter tools that have a high spindle speed, and this improves the accuracy of cutting.
Machines having a lesser number of axes usually involve multiple workstations, and the workpiece moves through multiple stages before becoming complete. In a 5-axis CNC machine, additional workstations are eliminated, and the machine part is completed within one workstation, hence drastically reducing the chances of errors.
This ensures consistent product quality, which is particularly useful in the production of custom aluminum machining parts wholesale, where thousands of parts having intricate designs should be identical to each other.
All in all, precision in CNC machining stands as the cornerstone of modern manufacturing excellence. Its paramount importance cannot be overstated, as it underpins the production of intricate components across a wide array of industries, from aerospace to healthcare.
The pursuit of precision not only ensures the creation of high-quality, reliable parts but also contributes to increased efficiency, reduced waste, and cost savings. In a world where technological advancements continuously push the boundaries of what is possible, precision in CNC machining allows us to transform designs into reality with unwavering accuracy and reliability.
