Methods of avoiding deformation of parts during processing of aluminum profiles

Aluminum is an important industrial raw material. However, due to its relatively low hardness and large coefficient of thermal expansion, aluminum profiles are easily deformed when processed into thin-walled and sheet-metal parts. In addition to improving tool performance and pre-stressing the material, several steps can be taken to minimize deformation of the aluminum profiled material.

When the demand for aluminum profile processing is large, excessive heat concentration must be avoided to generate better heat dissipation and reduce thermal deformation. The approach that can be taken is called symmetrical processing.

For example, imagine that a 90mm thick aluminum sheet needs to be milled to 60mm thick. If the milling face is immediately flipped to the other side, since each face is machined to its final size, the continuous use of aluminum profiles will have a large machining allowance, which will cause heat concentration problems and the flatness of the alloy plate can only reach 5 mm .

However, if the symmetrical processing method on both sides is used repeatedly during the processing of aluminum profiles, each surface can be processed at least twice until the final size is reached, which is conducive to heat dissipation, and the flatness can be controlled at 0.3mm.

When there are multiple cavities on an aluminum profile machined part, it is easy to distort the cavity walls due to uneven forces. The best way to solve the problem is to use a layered multiprocessing approach, i.e. all cavities are processed at the same time.

However, instead of doing all the aluminum profile machining parts at once, the parts can be divided into several layers and machined layer by layer to the desired size. The force applied to the part will be more uniform and there will be less chance of deformation.

By selecting appropriate cutting parameters during the processing of aluminum profiles, cutting force and synthetic cutting heat can be reduced. In the machining process, if the cutting parameters are larger than the normal value, the cutting force will be too large, which will easily cause deformation of the parts, affecting the rigidity of the spindle and the durability of the tool.

Of all the factors of cutting parameters, the greatest influence on cutting force is the amount of depth of cut. However, although reducing the number of cutting tools is beneficial to ensure that the part is not deformed, it also reduces the processing efficiency.

The high-speed milling CNC machining can solve this problem. By reducing the depth of back cut, increasing the feed and increasing the speed of the machine, machining can reduce cutting forces and ensure machining efficiency.

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