Advantages Of Aluminum Alloy Machining – 5 Common Problems In CNC Aluminum Processing

1. Rotten teeth, sticking knife and unqualified finish of machined surface during tapping.

Aluminum alloy has soft properties and low melting point, so it is easy to have problems such as rotten teeth or sticking knife in poor processing environment. In addition to changing processing parameters, such as avoiding medium speed processing that is easy to stick knife, cutting fluid with good lubrication and cooling performance should be used.

2. Moldy non machined surface.

Most of the problems in CNC machining aluminum alloy are caused by cutting fluid. The lack of cutting fluid product design means that it is difficult to avoid problems in the machining process. The non machining of aluminum alloy has a sensitive response to the corrosion inhibition ability of cutting fluid, and mildew is one of its manifestations. Aluminum alloy mildewing is usually caused by insufficient aluminum corrosion inhibition ability of cutting fluid and insufficient microbial control ability of cutting fluid. The mildewing phenomena caused by the two reasons are different, but in most cases, the mildewing is caused by insufficient aluminum corrosion inhibition ability of cutting fluid. When mildew occurs, we should start with the improvement of corrosion inhibition ability of cutting fluid and the improvement of storage mode after machining.

3. The residue on the machined surface affects the later cleaning.

Aluminum alloy generally needs cleaning process after machining. If the cleaning ability of aluminum alloy cutting fluid is not good, it will produce residue on the aluminum alloy machined surface, affecting the appearance or later code spraying treatment. It is usually related to the design of emulsification system and cleaning process of cutting fluid products.

4. There is a lot of foam in the process.

Cutting fluid foam is usually avoided during machining. Inadequate cooling caused by foam and severe tool wear will result in poor machining results and low machining efficiency. Especially with the renewal of machine tools, the five axis machining center has higher requirements for cutting fluid foam, and the cutting fluid which is short of anti foaming and defoaming ability will cause abnormal elevation of liquid level, and trigger the liquid level alarm to make the machine tool stop working normally. The improvement of the performance of cutting fluid foam can be solved not only by adding defoamer but also from the system design of cutting fluid products.

5. Short service life of cutting fluid.

In the process of machining aluminum alloy workpieces such as piston, gearbox cylinder block and so on, there is a common problem of short service life of cutting fluid. The service life of cutting fluid is not only related to the frequency of groove changing and the cost of investment, but also affects the processing quality, on-site working environment and so on. The service life of cutting fluid is mainly reflected in the sticking and corruption of groove fluid after using for a period of time. Sticking makes it difficult for aluminum chips to separate from the surface of aluminum parts, resulting in indentation and corruption, which reduces the machining quality of cutting fluid and worsens the on-site working environment. Stickiness is related to the selection of emulsion system and the ability to control microorganisms in the design of cutting fluid. Corruption is related to the introduction of microbial nutrients in cutting fluid and the selection of sterilization and bacteriostasis system. Of course, it is also related to the use and maintenance of on-site cutting fluid.