Longguang Innovation Technology Park, No. 74 Zhen'an East Road, Xiaobian Society, Chang'an Town, Dongguan City, Guangdong Province
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How can we address the issue of deformation in aluminum alloy parts?
Aluminum alloy parts have a relatively high coefficient of thermal expansion, making them prone to deformation during thin-wall machining. When using free-forged blanks, the large machining allowances further exacerbate the deformation issue.
Today, let’s take a closer look at what measures should be taken when machining aluminum alloy parts with CNC to prevent deformation.
1 Optimize tool structure
Reducing the number of cutter teeth expands the chip space. Since aluminum alloys have relatively high ductility and undergo significant cutting deformation during machining, they require a larger chip space. Therefore, it is preferable to have a larger radius at the bottom of the chip groove and fewer cutter teeth.
2. Precision grinding of cutting teeth
Before using a new blade, you should lightly sharpen the front and back of the blade teeth with a fine oilstone to remove any burrs and slight serrations left over from sharpening. This not only helps reduce cutting heat but also minimizes cutting deformation.
3. Strictly control the wear standards for cutting tools.
After tool wear, the surface roughness of the workpiece increases, and the cutting temperature rises, leading to greater workpiece deformation. Therefore, in addition to selecting high-quality, well-ground tool materials, it is also crucial to strictly control the degree of tool wear; otherwise, built-up edges are likely to form. During cutting, the workpiece temperature must not be allowed to rise excessively in order to minimize deformation.
In addition, selecting appropriate cutting parameters is crucial for controlling deformation in aluminum alloy parts. During CNC machining, it is advisable to use higher cutting speeds and moderate feed rates, which can help reduce cutting forces and cutting heat, thereby minimizing the risk of part deformation. At the same time, adequate lubrication and cooling using a coolant are indispensable steps. Not only do they effectively dissipate the heat generated during cutting, but they also reduce friction between the tool and the workpiece, further suppressing deformation. Moreover, arranging the machining sequence reasonably—prioritizing the machining of areas that are particularly sensitive to deformation or first performing rough machining to remove most of the material allowance before proceeding with finish machining—is another effective strategy for controlling deformation. In summary, by comprehensively applying these measures, we can significantly improve the machining accuracy and surface quality of aluminum alloy parts and effectively address deformation issues.
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