In CNC machining centers, what are the common processing methods of aluminum parts?
In CNC machining centers, what are the common processing methods of aluminum parts? Aluminum parts are machined to the desired geometry using previously machined electrodes. It is inserted into the blank and forms a cavity or a specific hole. Another common method is the wire-cut aluminum machining process. It uses a wire that is drawn between two nozzles that sit above and below the billet. The wire is then moved along the desired trajectory and the desired shape is cut into the blank. Remember, you need a pointcut for this method.
A fairly novel method is aluminum machining and milling. The process is subtly similar to traditional machining. There is a cylindrical rotary tool that follows a trajectory programmed into the CNC EDM machine. However, this tool does not have any sharp edges. It's just a cylinder attached to a high pressure that vaporizes metal along its path.
Advantages of aluminum processing
Now that we know how the process works, let's discuss how this unusual method of removing material can benefit us? This approach has proven to be very useful and has many advantages. Let us list some of them and, based on these advantages, form the main industries where aluminum machining components can find better use.
The hardness and machinability of the part material does not matter. This is one of the most important points of aluminum machining, as it can machine even the hardest and most complex alloys. The best examples are nickel and titanium alloys used in the aerospace industry. They are a big pain if you want to grind them, they are harder to handle than aluminum pieces.
Precision and surface quality are sublime. This is true because the final quality of aluminum machining depends on the quality of the electrode it sinks and the quality of the wire for wire cutting. Both can be made very fine because they are mostly made of soft but conductive materials.
There is no thermal transformation in the material. The heat generated during the discharge process is very precise, but the area is very small. It is cooled by the dielectric liquid surrounding the part in seconds, so there is little heat generated during processing. Therefore, there is no thermal deformation or excess carbon on the surface of the material.
There are no remaining tensions. Material evaporates. It's not cut off and it's not stamped to the desired configuration. This means that there are no cutting forces at all, which removes any form of internal tension that always exists after the traditional aluminum machining process. Without these tensions, the machined part will not bend and its precision and quality will be much higher.
Good potential for automation and packaging processing. The wires are easy to program using a CNC machine. It is even possible to turn and handle parts at an angle. If multiple parts are required, the billets can be welded together and wire cut together with wire.
