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Selection and consideration of CNC machining tools for aluminum alloy parts
by：Yifeng Metal
2022-02-18
Selection and Consideration of CNC Aluminum Parts Machining Tools
With the improvement of people's living standards, people are more and more like things with metal texture, which also makes aluminum products more and more used in many industries. Compared to steel and superalloys, which is a soft metal, HRC is not as hard but tougher. Therefore, the requirements for tools are relatively high. If a high hardness tungsten steel cutter is used to cut soft metals, the cutting edge will break and the tool life will be short. The machining needs to be done with a high-quality tool with low hardness and non-stick. Only in this way can the knife increase the speed and efficiency of the machine.
How to choose machining tools for CNC aluminum parts?
in
When machining aluminum alloys cnc, especially in small allowance cutting and finishing, the cutting edge of the indexable insert is usually blunt, which often leads to a 'plough' effect, and the cutting edge is also prone to suddenly cut into the workpiece, causing cutting The force suddenly increased. The sudden increase in cutting forces resulted in oversized tools and excessive power requirements. The above problem is further complicated by the need for cutting edges. Finishing must be done with a sharp positive cutting edge. In order to ensure the metal removal rate during roughing, the cutting edge is required to have sufficient strength. Therefore, cutting forces, cutting edge penetration, chip formation, stability, and insert positioning and clamping are considered.
Machine Geometry
Machining Shapes
Tools for CNC aluminum parts have specific geometries that affect the quality of the final product. Blades come in different shapes to fit specific CNC tool holders. Aluminum tool blades are available in diamond, round, triangular and square shapes. Better part quality can be achieved with sharp-edged inserts. For example, for high-speed surface machining of forged aluminum, a 30o-35o blade is best. Turning forged aluminum with diamond inserts will result in a high-quality surface finish.
For machining tools, what factors do we need to consider?
Rake Angle and Approach Angle
The rake angle refers to the angle between the nose of the cutting tool and the clamped workpiece on the CNC machine tool. Depending on the position of the tool blade, the angle can be positive or negative. We prefer to machine aluminum parts with positive rake angles. Since it is a soft metal, we had to minimize cutting resistance throughout the production process.
During machining, the final quality of the product is affected due to the accumulation of chips around the tool. Positive rake angle ensures efficient chip handling. It also helps with temperature control by lowering the cutting temperature. This factor helps to provide optimum machining conditions for aluminum parts, extending insert life.
CNC milling rarely relies on rake angles. This is because the approach angle defines the relationship between the part and the position of the tool on the CNC tool holder. We use 90 degree timing due to the machinability of aluminum. It allows our specialists to perform different milling processes. These include face, slot and shoulder milling.
Diameter Factor
Release angle
This parameter also defines the relationship between the tool and the workpiece clamped on the CNC machine. In this parameter, the tool insertion is the reference point. Like the front angle, it can be positive or negative.
When machining CNC aluminum parts, whether rapid prototyping or mass production, positive clearance angle is recommended. The use of indexable inserts allows the operator to vary the relief angle. The release angle is between 20o and 30o, which can provide better surface finish for aluminum parts.
Aluminum Chipbreakers
Chip build-up can hinder high-speed machining of aluminum parts. Often, chips are sticky in nature, which creates challenges when managing the machining space on CNC surfaces. The chipbreaker design used in CNC machines is largely dependent on the rake and relief angles.
In mass production of CNC aluminum parts, a sharp and wide chipbreaker is recommended. Wider chipbreaker removes chips of all sizes.
The increasing consumption demand in key segments such as sheet metal manufacturing, custom metal works and sheet metal manufacturing have been driving the sales of and its derivatives worldwide.
Dongguan Yifeng Metal Co., Ltd.’s mission is to be the leading global innovator, developer and provider of custom metal parts custom metal works products, systems, and services.
Millions of women across the world suffer from sheet metal manufacturing. Are you also one of them who suffer from acne problem? now you will see some hope in Dongguan Yifeng Metal Co., Ltd.'s offer of . Click Dongguan Yifeng Metal Co., Ltd. to know more.
Dongguan Yifeng Metal Co., Ltd. will do this by managing our business with integrity and the highest ethical standards, while acting in a socially responsible manner with particular emphasis on the well-being of our teammates and the communities we serve.
With the improvement of people's living standards, people are more and more like things with metal texture, which also makes aluminum products more and more used in many industries. Compared to steel and superalloys, which is a soft metal, HRC is not as hard but tougher. Therefore, the requirements for tools are relatively high. If a high hardness tungsten steel cutter is used to cut soft metals, the cutting edge will break and the tool life will be short. The machining needs to be done with a high-quality tool with low hardness and non-stick. Only in this way can the knife increase the speed and efficiency of the machine.
How to choose machining tools for CNC aluminum parts?
in
When machining aluminum alloys cnc, especially in small allowance cutting and finishing, the cutting edge of the indexable insert is usually blunt, which often leads to a 'plough' effect, and the cutting edge is also prone to suddenly cut into the workpiece, causing cutting The force suddenly increased. The sudden increase in cutting forces resulted in oversized tools and excessive power requirements. The above problem is further complicated by the need for cutting edges. Finishing must be done with a sharp positive cutting edge. In order to ensure the metal removal rate during roughing, the cutting edge is required to have sufficient strength. Therefore, cutting forces, cutting edge penetration, chip formation, stability, and insert positioning and clamping are considered.
Machine Geometry
The ultimate goal of machining is to produce the best part that meets the design or customer-specific requirements. Specifications can be in the form of part thickness, load-carrying capacity, and dimensions. CNC machines can handle aluminum parts of all sizes and shapes with efficient tool sequencing and manipulation. Increased throughput requires the use of indexable tools. This type of tool allows the operator to change the tool insert when necessary, enabling multiple automated machining of aluminum parts. CNC tool inserts with different cutting edges are available for post-processing operations such as polishing and grinding aluminum parts. In a CNC aluminum machining environment, the performance of a tool insert depends on the shape, clearance and rake angle of the insert.
Machining Shapes
Tools for CNC aluminum parts have specific geometries that affect the quality of the final product. Blades come in different shapes to fit specific CNC tool holders. Aluminum tool blades are available in diamond, round, triangular and square shapes. Better part quality can be achieved with sharp-edged inserts. For example, for high-speed surface machining of forged aluminum, a 30o-35o blade is best. Turning forged aluminum with diamond inserts will result in a high-quality surface finish.
On the other hand, CNC machining of cast aluminum parts will require operators to use round inserts to improve quality. Cast aluminum has a rough surface. Machining with sharp tools will result in a poor surface finish. The shape of the tool insert affects CNC parameters such as feed rate, depth of cut and tool clearance. Sharper shapes will require smaller feed rates and greater tool clearance.
For machining tools, what factors do we need to consider?
Rake Angle and Approach Angle
The rake angle refers to the angle between the nose of the cutting tool and the clamped workpiece on the CNC machine tool. Depending on the position of the tool blade, the angle can be positive or negative. We prefer to machine aluminum parts with positive rake angles. Since it is a soft metal, we had to minimize cutting resistance throughout the production process.
During machining, the final quality of the product is affected due to the accumulation of chips around the tool. Positive rake angle ensures efficient chip handling. It also helps with temperature control by lowering the cutting temperature. This factor helps to provide optimum machining conditions for aluminum parts, extending insert life.
CNC milling rarely relies on rake angles. This is because the approach angle defines the relationship between the part and the position of the tool on the CNC tool holder. We use 90 degree timing due to the machinability of aluminum. It allows our specialists to perform different milling processes. These include face, slot and shoulder milling.
Diameter Factor
For the influence of radial cutting force, small and medium-diameter tools have poor rigidity and are more prone to deflection, while large-diameter tools are more stable and have different requirements for anti-vibration. In addition, it was found that the feed rate is not the main factor affecting the radial cutting force. The radial cutting force varies only slightly between different feeds of the tool (typically 0.25mm and 0.35mm per tooth). For a typical aluminum alloy cutter with a diameter of 25mm, the land on the insert is 1° and 0.1mm wide, which perfectly matches the curved cutting edge.
Release angle
This parameter also defines the relationship between the tool and the workpiece clamped on the CNC machine. In this parameter, the tool insertion is the reference point. Like the front angle, it can be positive or negative.
When machining CNC aluminum parts, whether rapid prototyping or mass production, positive clearance angle is recommended. The use of indexable inserts allows the operator to vary the relief angle. The release angle is between 20o and 30o, which can provide better surface finish for aluminum parts.
Aluminum Chipbreakers
Chip build-up can hinder high-speed machining of aluminum parts. Often, chips are sticky in nature, which creates challenges when managing the machining space on CNC surfaces. The chipbreaker design used in CNC machines is largely dependent on the rake and relief angles.
In mass production of CNC aluminum parts, a sharp and wide chipbreaker is recommended. Wider chipbreaker removes chips of all sizes.
The increasing consumption demand in key segments such as sheet metal manufacturing, custom metal works and sheet metal manufacturing have been driving the sales of and its derivatives worldwide.
Dongguan Yifeng Metal Co., Ltd.’s mission is to be the leading global innovator, developer and provider of custom metal parts custom metal works products, systems, and services.
Millions of women across the world suffer from sheet metal manufacturing. Are you also one of them who suffer from acne problem? now you will see some hope in Dongguan Yifeng Metal Co., Ltd.'s offer of . Click Dongguan Yifeng Metal Co., Ltd. to know more.
Dongguan Yifeng Metal Co., Ltd. will do this by managing our business with integrity and the highest ethical standards, while acting in a socially responsible manner with particular emphasis on the well-being of our teammates and the communities we serve.
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