Recently, aluminum milling has become popular. On CNC machines, such metal processing is most cost-effective. The automatic work cycle makes it possible to produce products in a larger volume with high quality. The exact dimensions of parts are often not obtained in other ways.
What is the basis for the choice of material for processing?
Milling aluminum on a home-made CNC is used to produce small batches of unique parts. Valued metal for its properties and low cost. The main advantages of aluminum include its strength at low weight, as well as its absolute resistance to corrosion. This material has low thermal conductivity, which allows its use in shipbuilding.
CNC milling of aluminum in Moscow is carried out at factories that manufacture parts for the space, aviation, and military industries. Due to the development of machine tool industry, there has been a noticeable decrease in the cost of CNC systems. In recent years, affordable compact models have appeared that every auto repair shop can afford.
Milling aluminum on a hobby CNC (4 axes) helps to obtain rare spare parts whose cost exceeds the cost of the machine itself and the material.
Advantages of working on automated cutting machines
High-quality milling of aluminum on CNC machines is obtained thanks to the proven processing technology. The process of improving equipment does not stand still, but already at the moment there are a large number of proven models for home workshops, industrial facilities, and manufacturers can offer unique models.
CNC milling of aluminum certainly requires skills in working with industrial equipment and knowledge in the field of metalworking. But labor costs for studying complex SCADA applications are reduced. The process of creating codes according to the drawings takes place directly on the machine screen by setting the coordinates and dimensions of the part, as well as the direction of movement of the tool.
Trust is only automated processing
The tracking system does not give a chance for an error in the geometry of the future product. And the simple principle of converting the created program and its verification in the simulation mode helps to determine in advance the direction of movement of the cutter and avoid errors. Thanks to this sequence, the manufacturing time of the part is reduced and the material provided is saved. The last point is important with a limited batch of aluminum blanks.
Milling of aluminum on CNC machines is reliable, and the manufacturer gives a guarantee of delivery of products on time. Without fear, you can provide him with his own blank, already having machined parts. Using the built-in SCADA-system, it will be possible to instantly transfer all sizes and areas to the machine memory. The likelihood of operator error is much less than with conventional processing.
The disadvantages of conventional processing
The surface of the part is ideal if CNC milling of aluminum is used. Novosibirsk, for example, has many enterprises operating the old fashioned way. But the products are markedly different in quality. The milling cutter has the property of leaving scuffing and bumps on the surface due to non-observance of the synchronism of the rotating part and longitudinal movement. All this is eliminated on modern equipment.
Cutter synchronization is carried out by advanced applications. The speed and direction are selected so that the time to carry out similar operations in the usual way is reduced. The surface is perfectly smooth, without scratches and scoring. Accordingly, the load on the tool and part is reduced, the wear of the rubbing parts is reduced.
The latest development in the field of fastening parts is a vacuum table. Aluminum is damaged quite quickly due to mechanical stress. Retention of hull and thin-walled products is carried out by the type of suction cup. At the same time, the compressor absorbs part of the coolant, which returns to the machine through the drain channels.
Additional benefits
Modern CNC machines use electronic components to measure the length of the tool. Monitoring is carried out periodically in the process of automatic cutting, which can significantly reduce the number of damaged workpieces when a poor-quality tool breaks from overheating. An automatic tool binding unit can also be installed to instantly recount the coordinate system of the part relative to the cutting edge.
Electronic components are often used to control the size of the resulting surfaces. Thus, the operator can make timely adjustments and comply with technological accuracy. Before carrying out measurements and the cutting process, it is also recommended to balance the tool, which is also easy to use when using electronic probes. Common systems are: Renishaw, Heindenhain.
Which machines have instrument calibration systems installed?
Heidenhain manufactures its systems similar to Renishaw sensors. However, the latter company is the most popular, and machine tool builders choose this system due to the simplicity of its adjustment and the replacement of spare parts. The latest developments are proximity sensors.
Renishaw is used in every machine of the Korean company Hyundai Wia. A micron sensitive probe is used for each instrument. For lathes, the milling cutter is controlled by a Q-setter, either automatic or manual.
All of these advantages of CNC machines help to speed up the process of technology, eliminate product defects. The quality of the parts obtained along with their quantity is improved, which is difficult to achieve without modern equipment.