Operation Skills to Reduce the Deformation of Aluminum Parts
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Operation Skills to Reduce the Deformation of Aluminum Parts
In the previous article “How to Reduce the Deformation of Aluminum Parts During Processing?“, we learned the process measures to reduce the deformation of aluminum parts during processing. Now we will share the operation skills to reduce the deformation of aluminum parts as follow.
- Improve the clamping method of the workpiece
For thin-walled aluminum workpieces with poor rigidity, the following clamping methods can be used to reduce deformation:
- For thin-walled bushing parts, if a three-jaw self-centering chuck or spring chuck is used to clamp from the radial direction, once it is released after processing, the workpiece will inevitably be deformed. At this time, the method of pressing the axial end face with better rigidity should be used. To locate the inner hole of the part, make a self-made threaded through the mandrel, sleeve it into the inner hole of the part, press the end face with a cover plate on it, and back it with a nut. The clamping deformation can be avoided when the outer circle is processed, thereby obtaining satisfactory processing accuracy.
- When processing thin-walled and thin-plate workpieces, it is best to choose a vacuum chuck to obtain a uniform clamping force, and then process it with a small amount of cutting, which can well prevent the deformation of the workpiece.
In addition, a packing method can also be used. In order to increase the process rigidity of thin-walled workpieces, media can be filled inside the workpiece to reduce the deformation of the workpiece during clamping and cutting. For example, pour a urea melt containing 3% to 6% potassium nitrate into the workpiece, and after processing, immerse the workpiece in water or alcohol to dissolve the filler and pour it out.
- Reasonable arrangement of procedures
During high-speed cutting, due to the large machining allowance and intermittent cutting, the milling process often produces vibration, which affects the machining accuracy and surface roughness. Therefore, the CNC high-speed cutting process can generally be divided into: rough machining-semi-finish machining-clear corner machining-finishing and other processes. For parts with high precision requirements, it is sometimes necessary to perform secondary semi-finishing and then finishing. After rough machining, the parts can be cooled naturally to eliminate internal stress caused by rough machining and reduce deformation. The margin left after rough machining should be greater than the amount of deformation, generally 1 to 2 mm. During finishing, the finishing surface of the part should maintain a uniform machining allowance, generally 0.2-0.5mm is appropriate, so that the tool is in a stable state during the machining process, which can greatly reduce cutting deformation, obtain good surface machining quality, and ensure the accuracy of the product.
The main factor that affects the processing accuracy and surface quality of aluminum parts is that deformation is prone to occur during the processing of such parts, which requires operators to have certain operating experience and skills.
As a professional supplier of CNC cutting tools, Our has launched some cutting tools special for aluminum parts, such as DLC coating end mills for aluminum, high polished end mills for aluminum, turning/ milling inserts for aluminum, etc. Do you know other skills to reduce the deformation of aluminum parts during processing?
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