CNC Zinc Machining: Tips, Techniques, Applications
In the field of precision engineering, CNC zinc machining is one of the most common methods. This blog will explore the tips, techniques, benefits and uses of CNC zinc machining to help readers fully understand this important machining process.
1、Different zinc alloy material processing methods
1.Milling
As a cutting-edge method for zinc processing, milling, especially advanced 5-axis CNC machining, is the first choice for producing complex parts. It is capable of processing complex and diverse shapes.
2.Turning
Turning is often used to make cylindrical parts, and modern lathes offer multi-axis capabilities, including turning and milling operations
3.Drilling
Drilling comes into play when needed, and a variety of drills with spiral grooves can complete the task. Water cooling and sharp drills and generous cutting parameters prevent heat build-up and achieve efficient material removal.
4.Die Casting
Die casting is an efficient method for manufacturing zinc parts with complex designs and tight tolerances, using molds or dies to cast the required parts.
5.Electrospark Machining (EDM)
Although not a traditional machining process, EDM is a valuable method for making prismatic parts. Zinc’s excellent conductivity makes it suitable for EDM.
2、Choose the right zinc alloy
1.ZAMAK alloy
ZAMAK alloy is a mixture of zinc, aluminum, magnesium and copper. It has excellent strength, hardness and wear resistance. It is a popular choice for zinc CNC machining and is suitable for a variety of applications.
2.ZA alloy
When strength and elasticity are important, ZA (zinc aluminum) alloy has a higher aluminum content, is more powerful, more durable, and more resistant to deformation, suitable for heavy-duty tasks and high-temperature components.
3.Zinc copper titanium alloy
When strength, elasticity and corrosion resistance are important, zinc copper titanium alloy is the first choice. It has excellent dimensional stability and wear resistance, suitable for applications requiring stable performance.
3、Surface treatment of zinc alloy material processing
1.Electroplating
Electroplating with materials such as nickel and cobalt can produce a beautiful, corrosion-resistant and unique surface.
2.Chromate conversion coating
It can enhance corrosion protection and is available in a variety of colors, which is beautiful and practical.
3.Powder coating
Provides a strong, textured appearance that can withstand severe wear and tear.
4.Anodizing
Forms a thin and strong oxide on the surface of zinc alloys to enhance corrosion resistance.
5.Painting
You can choose a specific color for painting according to your imagination.
4、Zinc alloy material processing design skills
1.Draft Angle
Adding draft angle to the design ensures that the part ejects smoothly from the mold and reduces the risk of warping.
2.Uniform wall thickness
Adhere to a uniform wall thickness plan to avoid uneven cooling that causes part warping or cracking.
3.Fillet processing
Rounded corners can avoid stress points caused by sharp corners and prevent cracks or failures.
4.Feature positioning
Features such as ribs, bosses, and through holes need to be properly positioned and aligned with expected loads and stresses to ensure that the part is strong and durable.
5.Pay attention to undercuts
Reduce undercuts in part design to avoid disrupting CNC processing plans and reduce additional tools or steps.
5、Other tips to ensure effective zinc processing
1.Alloy selection
Choose alloys that are easy for machinists to work with, such as Zamak 3 or Zamak 5, to improve dimensional accuracy and save time.
2.Tool sharpness
Ensure that cutting tools are sharp to reduce tool wear and produce short chips that are easy to fall off.
3.Coolant use
Use plenty of coolant, such as the commonly used water-based coolant, to reduce friction and control temperature, improve surface finish and chip generation.
4.Cutting speed adjustment
When zinc alloys heat up, slightly increase the cutting speed to reduce cutting temperatures and promote better heat dissipation of chips.
5.Tool selection
Carbide tools are suitable for zinc alloy processing due to their excellent wear resistance and thermal stability; high-speed steel (HSS) is suitable for lighter tasks and works well with zinc alloy grades.
6、Benefits of CNC machining zinc
1.High precision
Impeccable dimensional accuracy is particularly valuable in industries such as aerospace, automotive and medical equipment.
2.Complex process
Excellent in processing complex shapes and designs, and has advantages in making customized parts.
3.High efficiency
Zinc has a low melting point and high CNC processing efficiency, which reduces tool wear, energy consumption and waste, and is cost-effective.
4.Green and environmentally friendly
Zinc is recyclable, CNC processing is environmentally friendly, produces less waste, and is a sustainable choice.
7、Application of CNC machined zinc parts
1.Automotive Industry
Strong, durable, and corrosion-resistant, used in engine blocks, transmission housings, and high-performance components.
2.Aerospace Industry
High precision and reliability, ideal for brackets, housings, and connectors, strength-to-weight ratio and corrosion resistance ensure performance under extreme conditions.
3.Medical Equipment
Good biocompatibility, strength, and corrosion resistance, used in surgical instruments, dental tools, and orthopedic implants.
4.Electronics and Telecommunications
Excellent conductivity and shielding performance, used in electrical connectors, heat sinks, and protective shielding.
5.Construction Applications
High corrosion resistance and durability, used in structural elements and decorative parts.
8、Conclusion
CNC machined zinc offers numerous benefits and its versatility makes it a smart choice for projects that require strong, corrosion-resistant parts with precise tolerances.