Basic skills of aluminum profile processing and aluminum component processing

Common complaints during aluminum profile machining and aluminum part machining include poor surface finish, sticky deposits on cut surfaces or tool edges, and a fuzzy appearance. All materials have different properties and require adjustment and care to obtain an optimal finish.

We want to understand the characteristics of aluminum, a soft and malleable metal with high thermal conductivity. The former means it can be cut easily, but will result in long stacks. The latter means it tends to generate heat. Following these tips when working with aluminum profiles and aluminum parts can help alleviate these problems.

Using the Right Cutting Tools for Aluminum Profile Processing

While aluminum is soft and malleable, it requires a good cutting tool for best results. Don't use high-speed steel or cobalt tools for the job; use carbide tools instead. Also, sometimes it is better to use a tool with fewer grooves. Since aluminum produces long chips, a tool with fewer grooves will allow chips to escape more easily. The right tool with the right number of pockets will allow you to use a wider range of spindle speeds.

keep cool

As mentioned above, aluminum part machining has high thermal conductivity. It gets hot as you cut, and the heat builds up quickly. This, in turn, can result in a hazy appearance, workpiece warpage and leading edge build-up (this stickiness problem). Proper coolant flow will keep chips away from the cutting area and keep the cutting surface properly lubricated.

horsepower control

While aluminum may be softer than other metals, it's still a metal, and it takes a lot of power to machine it. If your machine cannot meet the power requirements of the cut, it will cause chattering and skewing. When using smaller, lighter machines for aluminum milling, it may be necessary to use horsepower 'derating' in feed and speed calculations.

A Note About Chip Management

The high ductility during the machining of aluminum profiles results in long uninterrupted chips that can be quickly built up around the tool. This can lead to tool breakage, leading edge buildup (more sticky issues) and heat buildup (paint finish). When cutting aluminum, take care to clean the swarf. Whether it's a stationary blower system, high coolant flow or a chip conveyor, chips should be removed into your process.

Aluminum is malleable, lightweight, thermally and electrically conductive, and has excellent strength properties. With a few tweaks to machining techniques, it can be an ideal material for many parts and projects.

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