CNC Milling of Aluminium
CNC (Computer Numerical Control) milling of aluminium is a process that has speeded up work during metal processing and production itself. It has made it possible to create complex shapes and precise components from this versatile and common metal. Through the use of numerically controlled machines, it has facilitated the achievement of unprecedented accuracy and increased the repeatability of operations.
What is CNC milling of aluminium?
It is an activity that allows this lightweight but strong metal to be accurately formed and processed. In practice, computer-controlled cutting tools remove layers of material from the workpiece. This allows us to create shapes and details that would be impossible with conventional methods.
CNC technology also enables the automation and robotisation of the process, resulting in increased productivity and minimising the risk of errors.
Korzyści płynące z frezowania CNC aluminium
Here are some of the key benefits for its use:
- Precision at the highest level: With CNC technology, we can achieve dimensional and shape accuracy.
- Repeatability of the process: The automation of the process ensures that every manufactured part is identical.
- High productivity: CNC milling allows large quantities of material to be processed quickly and efficiently.
- Material – corrosion resistance: Aluminium (e.g. PA38) is naturally corrosion-resistant.
These advantages make CNC milling of aluminium indispensable in many modern production processes, offering both high quality, lightness, strength and efficiency.
CNC milling techniques for aluminium
A variety of techniques can be used for the milling of aluminium alloys, depending on the specific nature of the project and the complexity of the shapes to be created. These include 2D, 3D,4D and 5D milling. Each of these has its own unique characteristics and applications, which we will describe in detail below.
2D machining is a cutting technique that enables material to be machined smoothly in the XY axes. It is one of the fundamental methods we use for our aluminium milling services. With this technology, we can precisely cut shapes and contours on flat surfaces and create components such as:
- panels
- panels
- housings
CNC 3D milling is a step-change machining process that enables material to be processed smoothly in the XYZ axes. With simultaneous movement in three axes, we can create products with a variety of geometries. 3D CNC machining of aluminium is often used in industries where high precision and complexity are priorities:
- casting machining
- valve seats
- connection plates
4D milling is a technique that adds an additional A-axis to the standard three XYZ axes, enabling smooth 4D operation in the XYZA axes. This allows us to perform more complex operations, such as milling curved or helical surfaces. CNC aluminium punching using this technology is ideal for the production of parts with complex shapes that require accurate and multi-axis tool movement.
CNC 5D machining is the most advanced machining process, which enables material to be processed smoothly in the XYZAC axes. With simultaneous movement in five axes, we can create the most complex shapes. 5D light metal machining is used in the production of the highest precision components such as:
- aerospace components
- injection moulds
- dies
Aluminium milling methods
When it comes to aluminium milling, the shaping method is one of the most commonly used approaches. This technique involves the careful removal of material using cutting tools such as cylindrical, spherical or conical cutters.
Rolling is another technique that involves passing a sheet of aluminium between rollers. The rollers gradually reduce the thickness of the sheet and form the desired shape. This method is particularly effective in the production of thin and uniform sheets of aluminium. Also in this method, the use of computer control enables the process to be carried out accurately, quickly and highly efficiently.
Peripheral is a milling technique in which the axis of the cutter occupies a position parallel to the surface to be machined. It is used for working on large surfaces from which material must be carefully and evenly removed.
Face milling is a technique in which the axis of the cutter occupies a position perpendicular to the surface being machined. It is a method used for face milling, enabling material to be removed from the face of a workpiece. The face technique is used to create flat and smooth surfaces.
Beveling is a CNC machining method in which the axis of the cutter is at an angle to the machined surface. This method allows for oblique processing and the removal of material at an angle. This technique is mainly used to create complex shapes and details.
Counter-rotating milling is a technique in which the edges of the blades move opposite to the reciprocating movement of the workpiece. It enables the creation of smooth and even surfaces.
What Materials and Tools are needed when CNC machining Aluminium?
Aluminium alloys are a combination of aluminium with other metals that increase its mechanical properties, such as strength and machinability. With additional components such as copper, magnesium or silicon, aluminium alloys are stronger and easier to machine, e.g. aluminium 2017, aluminium 5083, aluminium 5754, aluminium 6061, aluminium 6082, aluminium 7075.
In the context of CNC machining, aluminium alloys are favoured for their ability to maintain precise dimensions and shapes. This makes them an ideal material for the manufacture of components requiring high accuracy, such as:
- automotive parts
- aerospace components
- precision tools
CNC milling tools Aluminium
Carbide tools
Carbide cutters are cutting tools made from a material with exceptional hardness and wear resistance. Carbide, also known as carbide, is a metallic composite that combines the strength of metals with the hardness of ceramics. These characteristics make carbide cutters ideal for machining aluminium, providing long tool life and a high quality machined surface. They are also often chosen for their ability to keep the cutting edge sharp even under heavy use.
Diamond-coated cutters
Diamond cutters are cutting tools coated with a layer of diamond, the hardest known material. Thanks to their exceptional hardness, diamond cutters offer durability and precision. They are particularly useful in aluminium milling, where high surface quality and minimal tool wear are required.
In the context of CNC milling of aluminium, diamond milling cutters are often used for machining components requiring the highest precision, such as:
- optical components
- injection moulds
- dies
Their ability to maintain the sharpness of the cutting edge over a long period of time makes them the ideal choice for tasks requiring the highest quality.
Where is CNC milling of aluminium used?
The role of CNC milling in the automotive industry
The use of CNC milling in the automotive industry makes it possible to create such components necessary for the construction of modern vehicles as, for example:
- Engine blocks
- Cylinder heads
- Gearbox housings
- Various types of fixtures and fittings
Such features of the CNC milling process as accuracy and repeatability are important in the automotive industry, where each component must meet stringent standards and specifications. The use of aluminium – a lightweight and corrosion-resistant material – in this industry is also apt.
The importance of CNC milling in the aerospace industry
CNC milling is used in the aerospace industry to create the intricate shapes and details required to build the latest aircraft and helicopters, such as:
- Structural parts
- Panels
- Mounts
- Various types of fasteners and connectors
In the aerospace industry, aluminium is the preferred material not only for its lightness and strength, but also for its resistance to extreme conditions.
Process flow for aluminium machining with CNC milling at CPP PREMA
| No. | Operation | Workstation | Work Cell |
|---|---|---|---|
| 1. | Cutting | Circular Saw | Cobra 350AX |
| 2. | Deburring | Belt Grinder | SUT-2 |
| 3. | Drilling | CNC Machining Center | Chiron FZ 15W |
| 4. | CNC Milling | CNC Machining Center | Chiron FZ 15W |
| 5. | Inspection I | Measurement Station | NJ |
| 6. | Deburring | Bench Grinder Station | Work Station |
| 7. | Anodizing | Soft Anodizing Unit | Plating Station |
| 8. | Inspection II | Measurement Station | NJ |
What influences the aluminium milling process?
The aluminium milling process is influenced by many factors that can determine the quality and efficiency of machining. Here are some of the most important ones:
- Type of cutting tool: The choice of the right tool, such as carbide cutters or diamond cutters, is decisive for the quality of machining.
- Cutting parameters: Spindle speed, feed rate and depth of cut must be adapted to the properties of the aluminium and the requirements of the project.
- Cooling: Effective cooling of the tool and material prevents overheating and increases tool life.
- Clamping stability: Aluminium must be securely clamped on the work table to prevent it from moving during machining.
- Material quality: The mechanical properties and structure of aluminium can affect the ease of machining and the quality of the final product.
By taking these factors into account, it is possible to optimise the milling process and achieve high quality workpieces.
How do I prepare a project for aluminium milling?
Preparing the project for aluminium milling is a stage that influences the final machining result. The procedure proceeds in the following steps:
- 3D model creation: Design begins with the creation of an accurate 3D model in CAD software.
- Material selection: Selection of a suitable aluminium alloy that meets the mechanical and technological requirements of the project.
- Determination of cutting parameters: Based on the properties of the material and the geometry of the workpiece, the optimum cutting parameters such as speed, feed rate and depth of cut must be determined.
- Machining simulation: Running a machining simulation in CAM software allows the tool trajectory to be verified and potential collisions to be detected.
- CNC programme generation: Based on the 3D model and cutting parameters, a CNC programme is generated to control the machine during machining.
Preparing the design carefully and accurately avoids milling errors and achieves a high quality final product.
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In summary, CNC milling of aluminium is an extremely precise and efficient machining method. Which makes it possible to obtain excellent quality parts, perfectly tailored to individual production needs. Thanks to the qualified staff, experience, modern machinery at our disposal, it is possible to achieve even the most complex shapes and dimensions with the highest accuracy.
If you are looking for professional CNC milling services, we invite you to have a look at the full offer of CPP PREMA. We provide a wide range of CNC milling and conventional machining services, tailored to the specific requirements of our customers. For more information, please visit our website: CNC milling services.