Aluminum Alloy Product CNC Machining

Selecting an aluminum alloy model requires considering: 1) Strength requirements: For high-stress components, choose 7-series (7075) or 2-series (2024); 2) Corrosion resistance: For humid environments, choose 5-series (5052, 5083); 3) Machinability: For complex shapes, choose 6-series (6061, 6063); 4) Welding requirements: Prefer 5-series or 6-series; 5) Surface treatment: For anodizing, choose 6-series; 6) Cost factors: For general use, 1-series pure aluminum. For example, aerospace commonly uses 7075, automotive parts mostly use 6061, marine environments suit 5083, and decorative parts can use 6063.

Common problems and solutions in aluminum alloy machining: 1) Tool adhesion/chip buildup: Use sharp tools, increase cutting speed, enhance cooling; 2) Poor surface roughness: Optimize cutting parameters, use high speed with low feed rate, ensure tool sharpness; 3) Deformation: Use roughing and finishing separation, arrange cutting sequence reasonably, use special fixtures; 4) Burrs: Optimize tool angle (increase rake angle), reduce feed rate, add deburring process; 5) Unstable dimensional accuracy: Control machining temperature, use constant-temperature workshop, select stable material states (e.g., T6 state).

Effects of heat treatment on aluminum alloy machining: 1) Mechanical property changes: T6 state significantly increases hardness (6061-T6 hardness ~95HB), increasing machining difficulty; 2) Machining efficiency: Annealed state (O-state) machining efficiency is 30-50% higher than aged state; 3) Machining sequence: Typically use "rough machining - heat treatment - finish machining" process to avoid heat treatment deformation affecting final accuracy; 4) Dimensional stability: Heat treatment releases material stress more fully, improving dimensional stability; 5) Surface treatment: Heat treatment state affects anodizing results. For high-precision parts, stabilization treatment after heat treatment is recommended to reduce subsequent deformation.

Common aluminum alloy surface treatments and characteristics: 1) Anodizing: Forms porous oxide film, can be dyed, improves corrosion resistance and wear resistance, thickness 5-25μm; 2) Hard anodizing: Thickness 25-150μm, high hardness (≥300HV), excellent wear resistance, suitable for moving parts; 3) Electroplating: Chrome plating increases hardness and wear resistance, nickel plating improves corrosion resistance, gold/silver plating for conductive decoration; 4) Chemical conversion: Chromate treatment improves corrosion resistance and coating adhesion, chromium-free passivation is more eco-friendly; 5) Spray painting/powder coating: Good decoration, various colors, good protection; 6) Electrolytic polishing: Improves surface finish and corrosion resistance, suitable for medical and food equipment. Selection should be based on usage environment and performance requirements.

Aluminum alloy machining precision: Standard machining reaches IT7-IT8 grade (±0.015-0.03mm), precision machining reaches IT5-IT6 grade (±0.002-0.008mm), ultra-precision machining reaches ±0.001mm. Precision assurance measures: 1) Equipment: Use high-precision CNC machines (positioning accuracy ≤0.003mm); 2) Tools: Diamond or ultrafine grain carbide tools; 3) Fixtures: High-precision tooling fixtures to reduce clamping errors; 4) Environment: Constant-temperature workshop (temperature fluctuation ≤±1℃); 5) Measurement: CMM (accuracy ≤0.001mm); 6) Process: Use rough/finish separation, multiple aging, stabilization treatment; 7) Personnel: Experienced programming and operators. Full-process control ensures stable high-precision requirements.

Aluminum vs. other metals machining cost comparison: 1) Material cost: Aluminum price is ~2-3× ordinary steel, lower than copper and titanium alloys; 2) Machining efficiency: Aluminum machining speed is 3-5× steel, 8-10× titanium, shorter machining time; 3) Tool consumption: Special tools for aluminum last longer, cost ~1/2 of steel machining; 4) Energy cost: Machining energy consumption only 1/3 of steel; 5) Post-processing cost: Aluminum surface treatment (e.g., anodizing) costs less than steel electroplating; 6) Total cost: Although material cost is higher, higher efficiency and lower energy make total cost typically 10-20% lower than stainless steel, >50% lower than titanium, showing significant cost advantage.