Why use soft aluminum blocks for milling? Analysis of reasons and operating skills
Milling is a processing method that removes material from a workpiece by rotating a tool to form the desired shape and size. Among the many materials that can be used for milling, soft aluminum blocks have become a common material in milling due to their unique performance characteristics. The reasons for soft aluminum blocks for milling are detailed below in a number of ways.
1.Soft aluminum blocks for milling have good cutting performance
(1) Moderate hardness:
The hardness of soft aluminum blocks is relatively low, and its density is about 2.7g/cm³, which makes it less wear on the tool during milling. Compared with high-hardness materials such as steel and titanium alloys, the tool life is longer when milling soft aluminum blocks, which reduces the frequency of tool replacement and thus reduces processing costs.
For example, when processing aviation parts, although titanium alloys have excellent performance, their high hardness causes serious wear on the tool, while soft aluminum blocks can better protect the tool while ensuring certain performance.
(2) Small cutting force:
Due to the low hardness of soft aluminum blocks, the cutting force required for milling is relatively small. This means that under the same processing conditions, the machine tool has lower energy consumption and higher processing efficiency. For large workpieces or occasions that require long-term continuous processing, the use of soft aluminum blocks can significantly reduce energy consumption and improve production efficiency.
For example, in automobile manufacturing, when milling large aluminum parts such as engine cylinders, smaller cutting forces help maintain stable operation of the machine tool and improve processing accuracy.
(3) Easy to handle chips:
The chips generated by soft aluminum blocks during milling are relatively small and easy to handle. These chips will not easily wrap around the tool or workpiece like chips from hard materials, affecting processing quality and efficiency. At the same time, fine chips are also easy to collect and recycle, which is beneficial to environmental protection.
For example, in the processing of electronic product shells, the chips generated by soft aluminum blocks used for milling can be easily collected and processed, avoiding pollution to the production environment.
2.Soft aluminum blocks for milling have excellent thermal conductivity
(1) Good heat dissipation effect:
Soft aluminum blocks have good thermal conductivity and can quickly conduct away the heat generated during milling. This helps to reduce the temperature of the tool and workpiece, reduce thermal deformation and thermal damage, and improve machining accuracy and surface quality.
For example, in the processing of precision instruments, maintaining a stable temperature is crucial to ensuring the accuracy of parts, and the excellent thermal conductivity of soft aluminum blocks can meet this requirement.
(2) Extend tool life:
The heat generated during milling is one of the important factors leading to tool wear and failure. The good thermal conductivity of soft aluminum blocks helps to reduce tool temperature and extend tool life. This is of great significance for improving processing efficiency and reducing production costs. For example, in mold manufacturing, soft aluminum blocks for milling can reduce downtime caused by tool wear and improve mold production efficiency.
3.Soft aluminum blocks for milling are easy to process and form
(1) Strong plasticity:
Soft aluminum blocks have good plasticity and can be easily processed into various complex shapes and sizes through milling and other processing methods. This allows engineers to be more flexible in choosing materials and structures when designing products to meet the needs of different application scenarios.
For example, in the aerospace field, soft aluminum blocks for milling can be used to manufacture lightweight, high-strength complex structural parts to improve the performance of aircraft.
(2) High surface quality:
Soft aluminum blocks for milling can achieve higher surface quality and lower surface roughness. This is of great significance for some products with high requirements for surface quality, such as optical instruments and electronic products. At the same time, good surface quality also helps to improve the corrosion resistance and aesthetics of the product.
For example, in the processing of mobile phone shells, soft aluminum blocks for milling can produce smooth and delicate surfaces, improving the quality of the product.
4.Good economic and environmental protection of soft aluminum blocks for milling
(1) Low cost:
Compared with some high-performance metal materials, such as titanium alloys and nickel-based alloys, the price of soft aluminum blocks is relatively low. This makes milling soft aluminum blocks have a greater advantage in cost and is suitable for large-scale production and low-cost applications.
For example, in the manufacture of automotive parts, the use of soft aluminum blocks can reduce the procurement cost of materials and improve the competitiveness of products.
(2) Recyclable:
Soft aluminum blocks are a recyclable material. The chips and waste generated during milling can be recycled and reused to reduce resource waste and environmental pollution. This meets the requirements of modern society for sustainable development and is conducive to promoting the development of green manufacturing.
For example, in the processing of aluminum alloy doors and windows in the construction industry, the aluminum chips generated by milling can be recycled and used to manufacture other aluminum alloy products, realizing the recycling of resources.
5.Has a wide range of application fields
(1) Aerospace:
In the field of aerospace, soft aluminum blocks for milling are widely used in the manufacture of aircraft structural parts, engine parts, avionics equipment housings, etc. The light weight, high strength and good processing performance of soft aluminum blocks make them one of the important materials in the aerospace field.
(2) Automobile manufacturing:
In automobile manufacturing, soft aluminum blocks for milling are often used to manufacture engine cylinders, wheels, suspension systems and other parts. The use of soft aluminum blocks helps to reduce the weight of the car and improve fuel economy and driving performance.
(3) Electronic products:
In the field of electronic products, soft aluminum blocks for milling are used to manufacture the shells and internal structural parts of products such as mobile phones, computers, and tablets. The high thermal conductivity and good surface quality of soft aluminum blocks make them an ideal material for the shells of electronic products.
6.Operational skills for milling soft aluminum blocks
(1) Workpiece clamping and positioning
Correct workpiece clamping and positioning are important steps to ensure milling accuracy. When clamping soft aluminum blocks, suitable fixtures should be used to ensure the stability of the workpiece and avoid displacement or vibration during processing.
In addition, accurate positioning can ensure the processing size and shape accuracy of the workpiece. Common clamping methods include the use of vises, pressure plates, and vacuum suction cups. Reasonable clamping and positioning can improve processing efficiency and part quality.
(2) Tool path planning
Tool path planning has a significant impact on milling efficiency and surface quality. When planning the tool path, the idle time should be minimized to improve processing efficiency. At the same time, a reasonable tool path can reduce cutting force and vibration and improve the surface quality of the workpiece.
Common tool path planning methods include linear cutting, circular cutting and spiral cutting. Selecting the appropriate tool path according to the workpiece geometry and processing requirements can significantly improve the milling effect.
(3) Problem solving in actual operation
In actual milling operations, various problems may be encountered, such as tool wear, excessive cutting force, etc. Timely adjustment of cutting parameters or replacement of tools is an effective way to solve the problem.
7.Summary
In summary, the reasons for using soft aluminum blocks for milling mainly include its good cutting performance, excellent thermal conductivity, easy processing and forming, good economy and environmental protection, and a wide range of applications. These characteristics make soft aluminum blocks have great advantages in milling processing and become the preferred material in many industries.