Main difficulties in precision machining of aluminum alloys
Aluminum alloy is the main raw material for most machining plants and one of the easiest mainstream metals to process. Therefore, aluminum alloy precision machining has received widespread attention and popularity. At the same time, Cutting Edge Machining & Automation uses precision machining capabilities to ensure that your metal parts meet your high quality standards.
At the same time, this is also the reason why aluminum alloy machining is difficult. Since every machining shop can process aluminum materials, aluminum alloy CNC machining is a truly extremely competitive industry. Each machining shop has to continuously improve its competitiveness in order to maintain its competitiveness in the fierce market competition. own share.
If a shop only needs to machine a few aluminum parts, the efficiency of CNC machining of aluminum alloys doesn’t really matter. However, if the processing plant needs to process tens of thousands of aluminum parts every week, then the efficiency of precision machining of aluminum alloys is crucial.
The main challenge in efficiently machining aluminum is to achieve maximum aluminum material removal while still getting the product right. If the temperature is too high, the aluminum will melt and fuse to the tool. Therefore, even though aluminum is as soft as tofu and easy to cut, if the aluminum chips stick to the tool, it can easily create a friction welding effect between the aluminum chips and the aluminum part.
Another difficulty is tremor. When aluminum parts rotate at high speed, when the tool meets the aluminum part, strong tremors sometimes occur.
Machining characteristics of different types of aluminum alloys：
Aluminum 2011—The softest aluminum alloy, this is the easiest to work with of all aluminum grades. Corrosion resistance is poor, so it usually requires anodizing, but seriously, it’s hard to find an easier material to machine than 2021.
Aluminum 2024 – has a high strength-to-weight ratio, so 2024 aluminum alloy is often used when parts require good tensile strength. It can machine well, but there’s one thing to watch out for: It can create chips in that split second at the end of a heavy cut with the tool. For example, when performing full-diameter grooving. So the toolpath may need to be adjusted to soften the exit to prevent this. These chips are usually easier to deal with and don’t stick to aluminum parts as much. Another thing to watch out for is corrosion. The corrosion resistance of 2024 is very poor, so after machining, the lubricant on the surface must be dried quickly. Otherwise, the surface quality of 2024 aluminum parts will not be very good. Overall, though, the 2024 is easy to turn and mill.
Aluminum 5052 – Also a very soft aluminum material, often used in forming applications. For example, it is used for aluminum casings, or for aluminum ship parts, because 5052 has excellent corrosion resistance. But aluminum 5052 is not easy to machine because this aluminum alloy is highly viscous and can clog tools quickly. When turning and milling, you need to always ensure that the tool is very sharp and well lubricated, otherwise the surface finish of the product will be worn away and the tool will risk damage. If you keep your knives sharp, you can easily achieve a bright mirror finish.
Aluminum 6061—the most commonly used aluminum alloy material, has very balanced properties in all aspects. Very easy to cut and mill. Basically all machine shops are machining 6061 aluminum. Care should still be taken when exiting material in very heavy cuts, there is a slight risk of material chipping. The harder the material, the easier it is to work with. T4 is ideal for machining, with T6 a close second. Compared with 2011 aluminum alloy, the machinability index of 6061-T4 is equivalent to 90%, and that of T6 is equivalent to 80%.
Aluminum 6063—Material properties very similar to 6061, but more commonly used in aluminum extrusions. However, 6063 is not that hard. This makes 6063 a little harder to work with; it’s softer and more viscous.
When machining 6063 aluminum profiles, please use very sharp tools, good lubrication, and pay attention to chip removal.
Aluminum 7075 — This is very popular in structural components such as aircraft wing spars and bicycle frames. This is a very hard aluminum. Its mechanical properties are very good; the machining properties are not as good as 6061, but not worse than 5052. However, it is difficult to achieve a smooth and bright metallic effect on the surface of aluminum 7075 parts; it is more likely to result in a more smooth but dull grayish surface after machining.