Custom Your CNC Milling Aluminum Parts in China

Ruitai is a reliable supplier for CNC milling aluminum production,we have around 15 years of experience,and can custom many kinds of CNC milling aluminum parts for you

Just send the 3D files to us and you can get instant quote within 4 hours

FREQUENTLY ASKED QUESTIONS

What Is CNC Milling Aluminum?

CNC is a computer-operated program that commonly uses for item production and prototyping. Aluminium is a very common material used by machines. Because of its excellent machinability, it is the preferred material for most manufacturers.

Aluminium has some very interesting thermal and mechanical properties. In drilling processes, aluminium metal is easy to shape, like in CNC aluminium machining. These days the demand for aluminium has increased in machining industries. There are some things that you should know about CNC milling aluminum that are given below.

Figure1 CNC Milling Machine for Aluminum

What Is The Type Of Material CNC Milling Aluminum Consists Of?

Aluminum is a durable, lightweight, and soft metal. Its appearance is dull grey or silver, depends on the roughness of its surface. There are no magnetic properties, and it’s non-flammable also.

 How Can You Tell Which CNC Milling Aluminum GradeTo Use?

According to its characteristics, you intended to choose different aluminum grade according to its characteristics you require to rank its grade.

Here are some types of aluminum grades;

Aluminum 6061: This is a grade with superb mechanical properties. Grade 6061 is widely used for five-axis CNC machining because of its good strength, excellent corrosion resistance in harsh conditions.

Figure 2 Plates of aluminum 6061

Aluminum 7075: This grade is also tough, like aluminum 6061. This grade is well known for fatigue strength. However, this grade is not good for welding and even costly. Hence this grade is tough and aircraft wings, rock climbing kits. And bicycle parts are made of this material.

Figure 3 Plates of aluminium 7075

Aluminium 2024: This Aluminum is mostly used in the military and aerospace industry. This Aluminum is not weldable.

Figure 4 Aluminum 2024

What Is CNC Milling Aluminum Prototype?

Aluminum 6061-T6 is a very common type of alloy used for military, aerospace, electronics, and transportation.

Different types of methods are used for CNC aluminium Prototyping: dip moulding, five-axis machining, investment casting, waterjet cutting, and welding. The strength of tolerance is nearly equal to 0.01mm.

These CNC Milling Aluminum Prototype machines are well-known for manufacturing quality products and prototypes. Because of its advantages, this is the perfect choice for precision and milling aluminium.

What Parts Are Present In CNC Machined Aluminum?

The CNC parts manufactured by using Aluminum alloys, and you can use CNC Machines for several services. These parts of machined CNC aluminium are commonly used in engineering sectors.

Figure 5 different parts of CNC aluminium machine

Here is the name of machined CNC aluminium parts:

Front panels

Dowels pins

EMI-housing

Spline shafts

Lighting fixtures

medical devices

How to Avoid Deformation In CNC Milling Aluminum?

Aluminium is a very common industrial material. Because of its low hardness, it can be deformed when being machined into thin parts.

Figure 6 CNC Aluminum Machine

There are some ways that you should take to avoid deformation.

1. Symmetrical machining

This method results in lessening the thermal deformation rate.

2. Stratified multiple machining

By twisting one cavity wall, you can pretend several cavities on aluminium alloy. It would be best if you processed all cavities at the same time to avoid such an occurrence.

3. Get an appropriate cutting parameter.

To maintain quality and reduce the number of cutting, you should Increase the machine’s speed and reduce the cutting force.

4. Drilling and milling

The milling cutter is applied to the cavity and parts. It is sufficient, but it leads to cutting heat, expansion, and deformation. Using pre-drilling with the bigger tool, you can avoid this problem.

Which Aluminum Is Best For CNC Milling Aluminum?

As you know, there are different shapes and grades of Aluminum available in the market, But the point is, what is the best type of Aluminum for milling? This entirely depends upon which metal allow you to prefer to use.

Just assume you are doing a project in which the welding method is highly important and needed, then Alloy 1100 has to be the great and the most appropriate choice for you. This allows an excellent weldability percentage and allows you to carry on your manufacturing procedure easily.

Also, if you select this alloy, you must know that you can neither utilize it for high-strength nor high-pressure processes as it might not be suitable enough for it.

What Factors Should You Consider While Choosing An Aluminum Grade For CNC Milling Aluminum?

While you are going to select the aluminium grade for machining, first consider the following important factors:

1. Heat treating
2. Workability or formability
3. Machining
4. Strength
5. Typical end-user applications
6. Weldability
7. Corrosion resistance

Is The Weldability Of The Aluminum A Key Factor In CNC Aluminum Milling?

Welding is the key factor for CNC milling; most aluminium alloys weld isn’t as strong as the parental material. But not many people realize that because Aluminum has many other factors that make it valuable for CNC aluminium milling. Different aluminum alloys such as Alloy 7075, which has poor Weldability, Alloy 1100, has excellent Weldability, and grad 6063 hold good Weldability character.

Is The Formability Of Aluminum Important For CNC Milling Aluminum?

• Alloy 7075 – poor formability
• Alloy 2011 – good formability
• Alloy 6061 – acceptable formability
• Alloy 2024 – good formability
• Alloy 5052 – acceptable formability
• Alloy 3003 – excellent formability

Is Machining An Important Aspect For CNC Milling Aluminum?

Aluminum Alloy 707 is best in annealed condition because of its fair machinability. Alloy 1100 has good machinability and best to use for hard temper. Aluminum Alloy 2011 has excellent machinability and good for CNC aluminum milling. Alloy 6061 is machinable and works only for T4 and T6 tempers. Alloy 2024 works perfectly in annealed condition because of its fair machinability. Alloy 5052 has fair machinability, and these alloys are better for hard temper.

What Are The Applications Of CNC Milling Aluminum Parts In The Industry?

As I mentioned above, aluminum alloy has too many properties. That’s the reason it is used in several industries such as:

• Electrical: because of its high-level conductivity, it is used as electrical components in electrical appliances.
• Aerospace: The aerospace industry needs high strength and weight ratio because of the aerospace industry’s properties.
• Automotive: as I mentioned above, CNC machined Aluminum is used for components in the automotive industry.
• Sports: it plays a role as baseball bats and whistles in the sports industry.
• Food/Pharmaceutical: Most organic substances do not react with aluminum alloys. Therefore, it is considered useful and important in these industries.

Is Aluminum The Best Choice For CNC Milling Aluminum Plan?

Aluminum material is the most appreciable and appropriate selection for the CNC Milling Aluminum plan. The reason is its physical properties which are highly appreciated and useful in this process. It has an oxidized outer layer, which is resistant to corrosion from elements.

The reason Aluminum is great to be used for mechanical parts is its strength and strongest characteristics. All these industries make Aluminum very popular among all industries such as healthcare, aerospace, and automotive.

How EDM Work For CNC Milling Aluminum Parts?

Electronic discharge machining is commonly used to remove material from the workpiece’s surface by the electrical removal erosive process. Aluminum parts are highly appreciable when it comes to machining. It is because you can achieve some complex parts only with EDM’s help.

If you only use CNC machining on parts characterized with a deep structure that is difficult to clear corners, it will leave a large radius at the corners. But when you use the EDM process, you can get sharp edges. Blind cavities, Sharpe corners, intricate details, thin walls, and fine surfaces are some other EDM applications.

How Wire EDM Work For CNC Milling Aluminum Parts?

You can use the method of wire EDM for cutting metals and other conductive materials. In this controlled method, a travelling wire disintegrates material.  You can use a metallic wire of a diameter between 0.1 and 0.3 as an electrode. You can create any wanted shape with the part that is to be cut.

Figure 7 Aluminum wire cut EDM machine.

How is EDM Different from Wire EDM in CNC Milling Aluminum Parts?

EDM  is different from wire EDM, as there are differences in the type of electrode used during the process. There is no requirement of a pre-drilled hole in EDM as well as we can achieve 3D capacities. While with wire EDM, we can manufacture 2D parts only.

How Much Cutting Force And Power Is Required For CNC Milling Aluminum?

Aluminium’s power requirements in CNC Milling are lesser than other usual requirements because of the mechanical properties of Aluminum. Simultaneously, the cutting force is obligatory to a similar machine in which tensile and metals of machines are directly proportional to each other.

Which Conditions Affect The General CNC MillingOf Aluminum?

You are already aware that speed and cutting force is proportional to the power requirements for machining. While we use the CNC machining, power needs for aluminum machining reduce; unlike this, the cutting tool’s rank angle decreases. Here are some conditions that influence aluminum machining:

• The cutting force
• The cutting speed
• Depth of cut
• Feed

What Is Cutting Force In CNC Milling Aluminum?

Because of Aluminum’s mechanical properties, the power required to machining aluminum is less than it might be expected. The cutting force is the total force required to cut tools using the materials and the alloys. The direction and amplitude of force differ by cutting processes such as drilling, milling, and turning. When you enable the optimization of the cutting process, these forces are measured and analyzed.

Aluminum force cutting force usually varies at low speed, like 30 to 60 m/min. When you increase the speed, the cutting force for different machining alloys such as alloy 2011-T3 rises slightly. But most of the alloys decrease in this case.

How Much is the Speed of Cutting In CNC Milling Aluminum?

The cutting speed of metals depends upon the quality of the machine and engineers controlling it. The more experienced the staff is, the better the machine is, the more will be the speed of cutting using the Aluminum alloy.

If you need to minimize the temperature and save time, you need to maximize the cutting speed to the extent that is practically possible. The increase in the speed above 30 to 60m/min will reduce forming a build-up edge, chips break more readily and finish.

As aluminium alloys’ cutting speed depends upon the machines and the workpieces, you must get the best machines. The high cutting speed is used for aerospace applications. For saving time and minimize the temperature rise, the cutting speed should be high. When you increase the cutting speed above 30 to 60 m/min, it reduces the built-up edge. Chips will break more readily, and you will get improvise finish look.

How Can Deep be the Cut CNC Milling Aluminum?

If you want to remove the number of cuts required, the cut’s depth should be as high as possible, limits of equipment, the strength of parts, machine tool power, and amount of stock to be removed. The speed and quality of cutting enhance with the increase of depth of the cut. You can control the use of depth of cut to reduce the cause of distorting the workpiece, nor overload it.

If you are looking forward to getting a perfect manufactured product, it is appreciable to have an increased depth of cut within the machine’s limits. The depth can be enhanced to a great extent, keeping in view the machine tool’s power, checking types of equipment, and the sock amount to be removed. This will help you minimize the number of required cuts and increase the products’ outlook and quality.

What Is The Feed-In CNC Milling Aluminum?

Feed depends on your finished workpiece with strength, desire, and rigidity. It would be best if you used the alloys with a machinability rating of D and E. Those machines are best with a feed-in lower end of the range.

The aluminum machining feed depends on the finished desire, the machine’s rigidity, and its strength. If you want a finishing cut, you will need a light feed of around 0.05 t 1.5 mm/rev. In case of rough cuts, you can utilize the feed around 0.15 to 2.03 mm/rev.

What Are The Tips To Improve CNC Machining Aluminum?

To improve the machining aluminum, you should take care of your machine by keeping the cutting edge sharp. For preventing damage to the workpiece, chips must be broken by a chip breaker. Here are a few steps you can take to improve machining aluminum.

Figure 8 working of Aluminum CNC machine

Speed cutting: The speed also does matter in improving and productivity of machining aluminum. Aluminum usually likes to cut at a higher speed, so you can speed up while keeping the feed rate and cutting moderately constant.

Thermal stability: As you know, Aluminum alloys can be affected by temperature variations. Therefore a machine tool is designed for optimizing thermal stability by structurally, hardware and software. It will help to prevent effects on machining aluminum.

Spindle horsepower: Aluminum alloys consume more horsepower on aggressive speeds and feed rates. However, It is more free cutting than a harder material. The spindle you choose should be capable of a good horsepower rating for your application. Such a spindle should be capable of a speed of more than 12,000 RPM.

CNC control: CNC control plays an important role in improving milling aluminum alloys. Machining complex shapes in aluminum alloys require a high-level CNC control system that enables you to programs multiple axes, support NURBS programming, interface with multiple CAD/CAM software, etc.

Chip conveyor: During machining aluminum, aluminum chips can create a bottleneck to your workflow, and standard hinge belt conveyers may not work properly according to your machine operation demands. To prevent this problem, self-cleaning and filtering the chip conveyor.

Flood coolant: To increase efficiency in machining aluminum alloys, you should take the chips and increase the cutting area’s distance and apply a high-pressure coolant during many machining operations.

What Are The Benefits You Get When You Use CNC Milling Aluminum?

Aluminum is the most popular in CNC machining and is widely requested in the prototyping and production process. Its popularity is that Aluminum can be the machine at high speed, unlike iron or steel.

Many other plastics and metals can give you the same benefits as Aluminum, but Aluminum is where you can get unique benefits of their own while using it.

Benefits of  CNC Aluminum Machining

• Recyclability
• Electrical conductivity
• Strength-to-weight ratio
• Corrosion resistance
• Machinability
• Anodization potential

How Is Recyclability Of Aluminum Impactful In CNC Milling Aluminum?

One of the most prominent benefits you can get while using Aluminum is its high recyclability. Due to this factor, Aluminum is beneficial if you want to control the material wastage or for those companies seeking to minimize their environmental impact.

  Figure 9 recycling of Aluminum wastage

Businesses who want to recoup their expenditures must use Aluminum for the machining process. In CNC machining, recyclability is a crucial factor. When you use the CNC machining program, cutting tool produces a huge amount of waste material.

Why Are CNC Milling Aluminum Parts Useful For Electrical Components?

Due to the electrical conductivity of Aluminum, CNC machined aluminum parts are useful. Aluminum can not be conductive as copper. The conductivity power of aluminum grade is 37.7 million times per meter( at room temperature). Some of the alloys, such as stainless steel, have lower conductivities than aluminum material as it has significantly more conductivity.

Do Aluminum Grades In CNC Milling Aluminum Differ Greatly In Their Resistance To Corrosion?

In the corrosion resistance, aluminum alloys have very small to large differences. You can find quite a few famous aluminum alloys for CNC machining which have great resistances. If you take alloy 6061 or 3003 as an example,  they give great corrosion resistance, and they are easy to mend without cracking or damaging them in any way.

Aluminum holds the degree of level in which it can easily stand the oxidization and chemical damage; aluminum grades are different. These aluminum alloys can offer you outstanding corrosion resistance like other aluminium grades on the lower side of the strength spectrum.

Is Aluminum Easy For The Machine In CNC Milling Aluminum?

The most common reason to choose Aluminum for machined parts is that you can utilize this material easily. Its looks more of a benefit for machinist manufacturing companies. But it has significant benefit for the business ordering part and the end-user who eventually use it.

 Figure10 Aluminum machineability

Aluminum is easy to machine due to its formability, and it can cut it quickly and accurately while using CNC machine tools. Aluminum CNC machines can meet tighter tolerances, and these machines can lead you to higher accuracy and repeatability.

What Is The Strength To Weight Ratio Of CNC Aluminum Milling Projects?

Aluminum’s best quality that makes it ideal for both aspect and mechanical parts is its physical properties. The two most important are metal and its lightweight strength. For these reasons, Aluminum become so much popular among automobile and aerospace companies.

You can take automotive and air crafting because, in these fields, parts can be machined with Aluminum. Despite this, grades of Aluminum offer different types of services. Due to the strength-to-weight ratio, you can use 6061 in the making of many parts. A notably high strength grade such as 7075 is good in marine applications and aerospace.

You may also see this video for further clarification.

CNC Milling Aluminum Parts Are Popular In The Electronics Industry?

Because of important aesthetic considerations, aluminum machined parts are popular in the electronic industry. Aluminum is receptive to paints and tints; that’s the reason you can treat Aluminum with anodization. It is a procedure o surface finishing; by doing this, you can thicken the part’s protective and oxidized outer layer.

Figure11 Machined Aluminum parts

When the machining of Aluminum is over, the process of anodization starts. When the anodization process takes place, the electrolytic bath is set in which electric current pass through. By doing this, you get more resistance to holding aluminum piece.

What Are The Alternatives Of Aluminum For CNC Aluminum Machining?

We have listed some of Aluminum’s best alternatives for you, this list emphasis on difference and similarities of Aluminum to the popular silver-grey metal.

 Figure 12 Alternatives for Aluminum

Metals

1. Magnesium

Magnesium is better than Aluminum for weight and machinability. If you compare both of them, you will notice that magnesium provides worse machining safety and corrosion resistance.

2. Copper

Aluminum shares many material properties with copper. Copper is better than Aluminum in electrical conductivity. It is useful for various electrical applications. But if we talk about pure copper, it is difficult to machine. That’s why it is of the metal that name as the worse for machinability.

3. Titanium

If you are looking for an Aluminum alternative and need a better strength-to-weight ratio, titanium is the best choice. Because titanium has the same weight as Aluminum, except it holds the strength twice in number. Same as Aluminum, it is highly resistant to corrosion.

But titanium is not preferable for commercial use due to its higher point cost. Although this material is the best choice for medical devices and aircraft components, its price can be prohibitive.

4. Brass

Brass is a better choice than Aluminum because of its aesthetic applications. It has a golden appearance, and you can easily machine this metal. But the price point of brass is slightly on the higher side compared to Aluminum.

Engineering Thermoplastics

1. Teflon

Teflon is a good machinable thermoplastic which is a highly electrical insulator. Teflon is resistant to high temperatures, which makes it an alternative for Aluminum for high-temperature applications. Unlike its resistance power, it does not offer you strength and friction.

2. ABS

ABS is better than Aluminum for thermal shock resistance. There are very few similarities between Aluminum and ABS, but it remains lightweight and versatile material for CNC machining. It is worse than Aluminum for strength.

3. PEEK

When you compare Aluminum with PEEK, you will notice PEEK is harder for the machine. Still, it is considered a good alternative for Aluminum because of its good thermal stability. It is also a good choice because of its high strength. It is best for medical use too.

The price of PEEK is higher than Aluminum, making it usable only for the materials in which Aluminum cannot be used. Otherwise, it may cost you a lot of money.

4. Delrin

Delrin is considered the best alternative to Aluminum as it gives electrical insulation. Due to this, it is best for mechanical parts. Like Aluminum, Delrin is highly reasonable because it offers machinability. Delrin is also known as POM, which has impressively high strength for plastic but a low melting point.

What Is Aluminum Extraction In CNC Aluminum Milling?

Extrusion is the process in which you pass the melted molten substance through an aperture. By doing this, an elongated component is produced with a continuous profile. In aluminum extrusion, malleable, machinable Aluminum such as 6063 are involved. After machining, extruded parts can cut in various ways while using the CNC machine centre.