Modern manufacturing relies on precision computer numerical control (CNC) machining to create complex components. When combined with aluminum, this technology helps engineers and manufacturers to create lightweight and durable components to fit a variety of industries including aerospace and consumer electronics.
Click here to read more about Aluminum CNC Machining Service in China - Lecreator
This article gives insight into aluminum CNC machining services focusing on the specifics of manufacturing processes, material properties, and factors to help you with your custom parts order.
For more in-depth information, you should view Aluminum CNC Machining Service Supplier - Lecreator
CNC Machining Services
What Does CNC Machining Mean?
CNC Machining follows a subtractive manufacturing process. This process uses computer controls on machine tools to automate a process. This differs from additive manufacturing (3D printing) as additive manufacturing focuses on building layers, and CNC machining focuses on removing material from blocks to create desired solid shapes. Each process is automated with digital design files to ensure each cut meets the required engineering specifications.
Types of CNC Machines
Machine manufacturers use a variety of machines to match the complexity of the part.
CNC Mills:
This machine uses rotating tools to cut and remove material from a workpiece. They work best when creating flat surfaces, slots, and holes.
CNC lathes:
This machine uses a workpiece that rotates while a cutting tool remains stationary to shape the piece. This is the preferred method for creating cylindrical parts.
CNC Routers
CNC Routers are like mills, but are usually designed to work with softer materials and larger sheets. Routers can perform very fast cutting.
The Advantages of CNC Machining Services
The biggest benefit of this method of manufacturing is how precise it is. CNC machines can work within thousands of an inch. Also, the process is very repeatable, producing parts that will all be identical to the first part, which is extremely important to the process of mass production and assembly.
The Benefits of Aluminum as a Material for CNC Machining
The Benefits of Different Aluminum Alloys
Aluminum is a very popular metal to choose for machining for a variety of reasons. One is that it weighs less than steel, making the material less heavy. Also, it still has a high structural strength. Aluminum also has high thermal and electrical conductivity, and resists corrosion. It is also non-magnetic.
Common Aluminum Alloys Used in CNC Machining
Aluminum 6061:
Typically, it is the most common and most versatile alloy. Other than its versatility, it is also strong, and has the ability to be welded. It is a preferred alloy for automotive parts and for structural components.
Aluminum 7075:
This aluminum alloy is very strong, and has about the same strength as some steels. Therefore, it is often used in aerospace applications where there is high stress on the materials.
Aluminum 2024:
This alloy is used in airplane structures that require high fatigue resistance, although it is not as corrosion resistant as 6061.
Benefits of Aluminum in Precision CNC Applications
Aluminum has great machinability. It's also more easily chipped than tougher metals like titanium or steel, so it places less stress on cutting tools. This allows for faster cutting speeds which in turn lowers costs by saving time. Aluminum is malleable, allowing for more complex designs without risking tool breakage.
Aluminum Parts CNC Machining Processes
Overview of the Machining Process
First, a CAD model (Computer-Aided Design) is built. Next, the design is transferred to CAM (Computer-Aided Manufacturing) software which converts it to G-code. G-code is the programming language that guides the CNC machine. A block of aluminum is clamped in the CNC machine. The tools then follow the programmed path to cut the part.
5-Axis CNC Machining
5-axis machining is the industry standard for highly intricate aluminum components with complex designs. 3-axis machines are able to cut in the x, y, and z directions. 5-axis machines are an upgrade as they add two more rotational axes. This allows the cutting tool to come in from almost any angle, cutting down on the number of setups needed and increasing overall machining efficiency.
CNC Milling Techniques for Aluminum
Two of the basic techniques used with aluminum are face milling and peripheral milling. Because aluminum is so soft, the material can easily deform and stick to a tool which is called a built-up edge. This process happens when too much heat is generated. This can be avoided with the application of coolant and at the right cutting speeds, to ensure precision is maintained.
Online CNC Machining Services
Online CNC Machining Services Benefits
The process to digitally manufacture products has improved the way people procure products. With digital manufacturing of CNC, engineers can get quotes, and guidance on design-for-manufacturability (DFM), all with a few clicks. This simplification has enabled faster designs and quicker production.
Selecting an Online CNC Machine Shop
Before choosing a supplier, check the quality and the scope of their offerings. Having an ISO 9001 certification means they comply with a recognized international standard for quality management and is a plus. In addition, check if they can accommodate your post-processing requirements and their lead times.
Ordering Custom Aluminum Parts Online
File Formats:
Ensure designs have been exported and are compatible with universal formats like STEP or IGES.
Quantity:
Notice how much the pricing differs if you are ordering a single prototype versus when you are ordering a low-volume production run.
Material Stock:
Check that the alloy you need is available and not out of stock (e.g., 7075 vs. 6061) so that lead times are not impacted.
Aluminum CNC Machining Tolerances and Surface Finishes
Machining Tolerances Explained
Machining Tolerances is a term used to describe the range in which a physical measurement can vary. It is typically +/- 0.125mm or +/- 0.005 in machining processes. There are also more stringent tolerances, necessary for medical devices or aerospace components, which can go down to +/- 0.025mm or +/- 0.001 in, but these tolerances come with a much higher cost due to the increase in the time and resources needed for production.
Surface Finishes in Aluminum CNC Machining
Some finishes that aluminum parts can have include the following:
Impacts of Tolerances on the Manufacturing Process
Imposing a bigger tolerance will affect the machine quality, speed, tooling and the overall process of quality control. With this in mind, stringent tolerances should only be applied on critical features like the mating surfaces.
Maximizing Project Success with Aluminum CNC
When creating custom precision parts, aluminum is undoubtedly the best material to use. It is versatile, easy to work with, and has great machinability. Different machining techniques, aluminum alloys, and finishing methods can help manufacturers improve designs and ease the CNC machining supply chain. These strategies help ensure that custom precision parts can be CNC machined with aluminum quickly and easily.
