Make some adjustments to CNC machining technology to achieve the best results for aluminum parts

Common complaints among people new to aluminum alloys include poor surface finish, colloidal deposits on cut surfaces or tool edges, and smeared appearance. All materials have different properties and require adjustment and maintenance to achieve the best surface effect.

Aluminum is a soft and ductile metal with high thermal conductivity. The former means it is easy to cut, but will produce long chips. The latter means that it is prone to heat. Following these tips when machining aluminum can help alleviate these two problems.

Use the right cutting tool

Although aluminum is soft and ductile, it still requires good cutting tools to get the best results. Do not use high-speed steel or cobalt tools for this work; please use carbide tools instead. In addition, sometimes it is better to use tools with less chip removal. Since aluminum produces long chips, tools with fewer flutes can make chips easier to escape. Using the right number of chip flutes and the right tools will allow you to use a wider range of spindle speeds.

Keep cool

As mentioned above, aluminum has a high thermal conductivity. It becomes hot when cutting, and heat accumulates quickly. In turn, this can cause smearing of the surface, warping of the workpiece and accumulation of the leading edge (adhesion problems). The correct coolant flow will move the chips away from the cutting area and keep the cutting surface properly lubricated.

power

Although aluminum may be softer than other metals, aluminum is still a metal, and machining it requires a lot of power. If your machine cannot meet the power requirements for cutting, it will cause chatter and deflection. When using smaller lightweight aluminum milling machines, it may be necessary to use horsepower "downgrades" in feed and speed calculations.

Chip management considerations

The high ductility of aluminum results in long, continuous chips that can quickly accumulate around the tool. This can lead to tool breakage, leading edge buildup (more adhesion issues) and heat buildup (soiled surface). When cutting aluminum, be careful to clean the chips. Whether using a fixed air supply system, high coolant flow or chip conveyor, chip removal must be integrated into your process.

Aluminum has good strength characteristics, toughness, light weight, thermal conductivity and electrical conductivity. By making some adjustments to the processing technology, it can become an ideal material for many parts and projects.