The aluminum parts currently processed are mainly divided into two categories: deformed aluminum alloy and cast aluminum alloy. So what kind of milling cutter is used to process aluminum alloy? Is it better to use a special milling cutter or a special tool for aluminum alloy to achieve better processing efficiency? This article discusses the best milling cutter for processing aluminum alloy from the aspects of aluminum alloy milling characteristics, processing tools, and cutting parameters.
Aluminum Alloy Processing Characteristics
Milling aluminum alloy has the following main characteristics:
Aluminum Alloy has Low Hardness
Compared with titanium alloy and other hardened steel, aluminum alloy has lower hardness. Of course, heat-treated or die-cast aluminum alloy has higher hardness. The HRC hardness of ordinary aluminum plate is generally below HRC40. Therefore, when processing aluminum alloy, the tool load is small. Because aluminum alloy has better thermal conductivity, the cutting temperature of milling aluminum alloy is relatively low, which can increase its milling speed.
Aluminum Alloy has Low Plasticity
Aluminum alloy has low plasticity and low melting point. When processing aluminum alloy, the problem of tool sticking is serious, the chip removal performance is poor, and the surface roughness is relatively high. In fact, the main problems of aluminum alloy processing are tool sticking and poor roughness. As long as the two major problems of tool sticking and processing surface quality are solved, the problems of aluminum alloy processing will be solved.
Tools Wear Easily
Because of the use of unsuitable tool materials, when processing aluminum alloys, tool wear is often accelerated due to problems such as tool sticking and chip removal.
What End Mills are Used for Processing Aluminum Alloys
Aluminum alloys are usually processed with 3 flutes aluminum milling cutters. Depending on the processing conditions, 2 flutes ball end mills or 4 flutes flat end mills may be used. However, SAMHO recommends that 3 flutes flat end mills be used in most cases.
Selection of Tungsten Steel Milling Cutters for Aluminum
The number of blades is generally 3, and the material is generally YG type cemented carbide, which can reduce the chemical affinity between the tool and the aluminum alloy. Generally, CNC tool brands have a series of special milling cutters for processing aluminum alloys.
High Speed Steel Material
High-speed steel aluminum milling cutters are relatively sharp and can also process aluminum alloys well.
Cutting Parameters for Milling Aluminum Alloy
High-speed and high-feed milling can generally be selected for processing ordinary aluminum alloys. Secondly, choose a larger rake angle as much as possible to increase the chip space and reduce the phenomenon of tool sticking. If it is a fine-machining aluminum alloy, water-based cutting fluid cannot be used to avoid the formation of small pinholes on the machining surface. Generally, kerosene or diesel can be used as a cutting fluid for machining aluminum plates.
The cutting speed of the milling cutter for machining aluminum alloys varies depending on the material and parameters of the milling cutter and the processing technology. The specific cutting parameters can be processed based on the cutting parameters given by the manufacturer.
