Guide to Reducing Errors in Aluminum Machining Production
One common interest amongst aluminum machinist is to maintain the accuracy of parts. This has given rise to a few searches on ways of keeping dimensional constancy. The studies cover several factors that are namely: micro-strain, elastic limits, and micro-creeps. Our team of experts also has in-depth facts on the mechanisms leading up to the causes. This is what is helping us come up with ways of reducing the errors in aluminum machining.
One key factor is dimensional constancy. This refers to the material’s ability to keep its shape and shape. It also has to remain within the expected tolerances over a given timeframe and environment. This article will further delve into the dimensional constancy of aluminum. In addition, we will cover the ways we use to counter errors that arise in aluminum machining Production.
Why Are We Covering Aluminum Machining Production?
Aluminum is one of the most common metals on Earth. It also serves an array of function in several industries ranging from automobiles, aerospace to construction. Its alloys are unique in nature and offer awesome features. However, aluminum machining comes at a cost, unlike steel. The main problem we face is the high thermal expansion coefficient of aluminum alloy. There are thus special measures in place when dealing with aluminum.
What Are the Problems We Face in Machining Production?
Aluminum machining methods like thin-wall forging and machining often have an add-on defect. Before we proceed any further, it is vital that we grasp the meaning of a few terms. These are namely:
- Recoupable dimension change
- Plastic strain
- Dimension flux
Recoupable dimension change does not vary with time and we can predict it. It entails thermal increase, elastic strain, and magneto strain. The plastic strain is not recoupable, varies with time, and arises from applied stress. Dimension flux is a change in the dimension that arises from internal stress. It may come from phase changes or moisture. This instability does not come from any external force.
Two core mechanisms result in dimension errors during aluminum machining include:
- Relaxing of residual stress
- Metallurgical fluxes.
There are various factors that influence the defects in aluminum parts. They mainly are the material aspects, parts’ shape, and action of the cooling fluid. We must control these errors if we are to ensure top-notch aluminum machining production.
How Do We Reduce Errors in Machining Production?
In our many years of service in the aluminum-machining sector, we have come up with an array of ways in reducing errors. Here are the key ways we are able to achieve this,
Lowering Internal Stress in the Metal Piece
Dimension fluxes mainly arise from internal stresses. This may be with or without external forces. There are two main ways of reducing errors in aluminum machining arising from internal stress. The first one is the vibration treatment of the work-piece. The second one is through the natural aging of the work-piece.
Another method involves deforming the plastic in a controlled way. We can achieve this using tensile or compressive loading. We only use this method on open die forgings. In addition, we can choose to apply the thermal treatment. This involves applying sub-zero treatment to aluminum in a cyclical way. This aids us in lowering the stress by up to 25%. The final method under our study is uphill quenching. It involves cooling the blank to -273 degrees then quickly heating it afterward using steam.
Improving the Tool’s Cutting Ability
Properly choosing the tooling parameter for aluminum machining has a direct effect on the outcome. It affects the amount of heat loss and cutting force. Here are the main parameters we look at choosing the tool structure.
- We first properly ground the tools for machining aluminum production. This enables us to apply back and side angles. We use larger rake angles on tools applicable to final touches. They also aid us in machining softer aluminum alloys since their cutting edges are more acute.
- We normally make a large back angle. This directly affects the wear and tear of its surface. In addition, it has an impact on the quality of the final finish. We sometimes use a smaller back angle. This is when there is a need for rough cutting and rapid feed rate. During precision CNC aluminum machining, we have to lower the elastic defects. We also have to ensure little friction between the work-piece and cutter.
Improving the Work-Piece Clamping
There are two main ways that we use to better clamp aluminum work-pieces. We do not use a three-clawed self-centering chuck to clump thin-walled cylinders. This since it causes errors. We thus opt for the end-face compression method. It entails compressing the end face with a cover plate then tightening with a nut. This method is more accurate. The second method involves using suction cups on thin-walled plates. It allows us to distribute the clamping force onto the thin plate evenly. This allows us to reduce the errors in aluminum machining. An extra method entails treating with a liquid medium to avoid clamping errors. In this case, we use urea and later rinse it off with water or alcohol. Contact us now if you have any inquiries or orders regarding expert aluminum machining production.
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