Tips to Manufacture Custom Aluminum Machining Parts

The machining industry has seen the demand for manufacturing parts on the rise every year. Therefore, leaving machine shop owners to complete the client orders as quickly as possible with precision.

With so much at stake, the custom machine shop owners need a material that is ideal for CNC machining. Aluminum is the right material for manufacturing machined parts, it presents ample benefits like easier machinability.

The machinists still face some common problems to get the precision they need, what they lack is the way to machine aluminum alloys in the right way.

This article provides the ways to machine aluminum that can be implemented to get the maximum out of the material.

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.

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.

#1. 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.

#2. 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.

#3. 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.

#4. 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.

#5. 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.

Summing it up

Aluminum is ductile, lightweight, thermally and electrically conductive, and has high strength. These properties are only beneficial when aluminum is machined properly, one needs to keep a checklist of the things before progressing with the manufacturing process which is the correct selection of tool, chip management, work on thin-walled aluminum parts, working with optimal cutting parameters and thermal considerations.