Choosing Machining Tool Inserts for CNC Aluminum Parts
Picking the right machining tools or tool inserts plays a key role in improving the quality of CNC aluminum parts. Aluminum is an abundant metal that is ideal for use across diverse industries. This non-ferrous metal is easy to machine and has the needed chemical and structural qualities to make it a material of choice for an array of uses. People sometimes think machining aluminum parts maybe tasking since it is a lightweight and less dense material.
Quite the reverse, these qualities make it the perfect metal for rapid prototyping. The efficiency of the CNC machines and accessory tools determine the machinability of different aluminum grades. Owing to its high rate of machinability, our experts can offset costs through structured mass production strategies.
At Creatingway, we strive to achieve optimum productivity of CNC aluminum parts. This is often by firstly, maximizing the software we take up for specific CNC machines. Secondly, we try to automate tool indexing. Lastly, we try to correctly match the sizing of CNC spindles. Over the years, we have come up with one of the easiest means for our production team to improve the quality of CNC aluminum parts. This is by properly choosing the correct tool inserts and machining tools.
How Do You Choose A Machining Insert for CNC Aluminum Parts?
Inserts refer to removable cutting edges that we screw on a cutting tool’s body and then later clamp on a CNC machine tool post. We can clamp the inserts onto the tool using either screws or proper glue. They are of common use in machining for rapid prototyping of CNC aluminum parts. Inserts are ideal for machining aluminum parts with large diameters. Moreover, they can handle larger feed rates and deeper cuts.
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Insert Geometries
The ultimate machining goal is to produce optimal parts that meet the design or clients’ needs. These needs may be in the form of sizes, part thickness, and load-bearing capacity. CNC machines are often able to handle an array of shapes and sizes of aluminum parts. We achieve this through proper sequencing and guidance. Increased production requires the use of indexable cutting tools. These tools allow our expert to change tool inserts when the need arises. This allows us to carry out multiple and auto machining actions on aluminum parts. CNC tool inserts often come with varied cutting edges. This allows us to take up post-treatment operations like grinding and polishing of aluminum parts. A tool insert’s performance when machining CNC aluminum parts depends on relief angle, insert shape and rake angle.
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Insert Shape
CNC aluminum part tools have unique geometries that affect the product’s final quality. The is an array of shapes to fit specific CNC tool holders. The ones for aluminum come in diamond, triangular, round and square shapes. We achieve better part quality by adopting acutely angled inserts. For example, a 30 degree-35 degree tool insert is ideal for high-speed surface machining of wrought aluminum. Our experts use diamond-shaped inserts in turning operations of wrought aluminum to achieve a high-quality surface finish.
Meanwhile, CNC machining cast aluminum parts requires our experts to use round inserts to achieve better quality. Since cast aluminum is rougher on the outside, using sharp tools results in a poor surface finish. Moreover, tool insert shapes affect CNC parameters like depth of cuts, feed rates, and tool clearances. For instance, sharper shapes need larger tool clearances and smaller feed rates.
What Angle Factors We Need To Consider For Machining Tools?
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Rake Angle and Approach Angle
Rake angle refers to the angle between the tip of the cutting tool in relation to the clamped workpiece on a CNC machine. This angle can be positive or negative with the position of the tool insert. We prefer machining aluminum parts with a positive rake angle. Since it is a soft metal, we must minimize the cutting resistance throughout the production circles.
As chips build up around the tool during machining, it impedes the product’s final quality. The positive rake angle ensures that the chip disposal is effective. It also contributes to temperature control by lowering the cutting temperature. This factor aids to provide the optimal machining conditions for aluminum parts and improves the insert’s working life.
CNC milling rarely relies on the rake angle. This is since the approach angle defines the relationship between the part and tool’s position on the CNC tool post. Due to aluminum machinability, we adopt a 90-degree approach angle. It allows our experts to carry out different milling processes. These include face milling, slot milling, and shoulder milling.
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Relief Angle
This parameter also defines the relations between a tool and clamped workpiece on a CNC machine. In this parameter, the tool insert is the reference point. It can either be positive or negative just like the rake angle.
When taking up CNC machining of aluminum part for rapid prototyping, we prefer using a positive relief angle. This allows our experts to better alter the relief angles. The most preferred relief angles are between 20 degrees and 30 degrees since they confer better surface finishes. We also employ wide chip breakers to aid in the removal of varying chip sizes that impede high-speed machining. Simply contact us if you’re looking for the perfect CNC aluminum part machining services.
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