What are the best practices for machining Aluminum?

@MaddieG Sure!

Check now

@ndavis
I would not say I have the best practice but mostly good enough for company workshop. I am an engineer, not a certified technician. The best practice would be get the settings from your machine and tool manufacturer. And if there is any contradiction you should follow their guideline instead of random guy on the internet.

You gave no background on you or your machine so I am trusting that you already have the machine setup, calibrate and done machining on wood/plastic before.

First step would be get a physical machining handbook, it should contain 90% recommended info for difference materials and bits.

1. Bits:
   Any bit that does not have Aluminium in the coating will work on aluminium. High-end coatings work better for &#;strong&#; alloys and last longer. Nevertheless, uncoated high-speed steel is fine to get started. There is no need to get solid carbide bits when you just started, they have more narrow working range and cost much much more so you need to dial it right from the start. High-speed steel and cobalt runs slower and shorter lifetime but can be re-sharpened. 2-5$ bits from China is too cheap, spending ~5-10$/bit get the job done before it breaks.
   If you have fixed bed (router) machine then go for 2-3 flutes bits. If the bed does move then you can go full 4-6 flutes as spindle is more rigid.
   For drilling, the flutes length should be 2x diameter longer than intended drill length. Drill point angle: 118° is enough for aluminium. Helix angle: 30° is good enough, 10° angle might be needed for harder aluminium alloy.

Once you are comfortable, go for black oxide coated drill bits and ZrN coated or solid tungsten carbide mill bit for rough cut would be my recommendation. Diamond coated or solid tungsten carbide for finishing.

2. Spindle speed:
   First number to look up is cutting speed: Vc (m/min) for material group. Non-ferrous materials are group N in ISO. Roughly 100-250m/min is usual for aluminium with >8% Si and 220-600m/min for <8% Si. While this does not change much, you should still get the correct number from catalogue or lookup similar tools.
   Spindle speed is now: n = Vc x / (pi x D)
   D being your tool diameter.

3. Milling:
   Table feed (mm/min): Vf = Fz x Z x n
   Fz being feed per tooth from catalogue. Usually 0.1-0.3 mm for aluminium.
   Z is number of tooth.
   n we just calculated.
   Step-down (Ap) and step-over (Ae) change depending on tool geometry so it totally depend on what you buy. Though aluminium is soft so sub 0.05mm step-over cut is difficult, there should be 0.05-0.1mm left for finishing cut.

4. Drilling, pretty much the same as other materials.
   Table feed (mm/min): Vf = Fn x n
   Fn is feed per revolution from catalogue.
   If you want to drill deep holes then you need to pay attention to pecking and pilot hole. Through holes need to slow down ~50% for the last diameter length.

CNC (Computer Numerical Control) machining needs have been on the rise in recent years in various industries, from medical to automotive to aerospace sectors. This technology has made part and component designs and production easier and faster than ever with more precision and accuracy. 

But, when it comes to partnering up with a professional CNC machining service provider, it&#;s important to review a few necessary facts to ensure high-quality part production, as not every company offers top-notch services. Let&#;s see what considerations to take.

Here&#;s What to Consider When Choosing CNC Machining Services

Most CNC machining companies design and manufacture parts leveraging CNC technology and advanced tools, like mills and lathes. The entire process is computer-controlled to achieve the exact precision and accuracy when cutting different materials to produce simple to complex shapes. CNC machines work with various metals and plastics to create refined pieces of equipment used in the automotive and aerospace industries. In fact, the industrial and medical sectors are embracing CNC machining services nowadays to build items and pieces accurately. 

So, no wonder selecting a CNC machining company is one of the major decisions for your business to achieve the level of standard required for CNC-designed parts and components for your field, isn&#;t it? That&#;s why it&#;s important to consider the following factors to choose the best for your CNC machining needs:

With competitive price and timely delivery, kaierwo sincerely hope to be your supplier and partner.

#1: Determine industry experience-

Although CNC machining and 3D printing both are used for part designs and manufacturing for medical, automotive, and aerospace sectors, the former requires expertise and high skills to operate the technology, while the latter doesn&#;t as it runs on a push button, which anyone can control. 

So, when selecting a CNC machining company to work with, research on their experience in the CNC machining industry and in delivering services using this CNC technology. Ensure that they have an expert team who understands how to use this equipment to create high-quality part designs. After all, designing items not meeting the specifications will end up a non-performing or unusable piece. As a result, a lot of time will be wasted, which means delay in product development and launch in the market. 

#2: Ensure they are reliable-

The CNC machining experts you are partnering up with to design and manufacture parts and equipment for your automotive or aerospace sectors must be reliable. To ensure that, the best thing to do is to take a closer look at their work history. For example:

• Do they offer customized solutions to your part design and manufacturing problems?
• Are they quick to respond? 
• Do they meet on-demand productions as per clientele deadline needs?

Also, check what their previous clients are saying about their quality control procedures, like if the outcomes are consistent. 

#3: Compare your budget and their charges-

Understand first how much you can spend on CNC-machined parts by creating a complete cost breakdown. Thus, you can have a clear cost comparison for different CNC machining manufacturers and understand if the price fits within your budget.

Note: It&#;s important to understand that high-cost options don&#;t always come with speed and quality guarantees. On the other hand, going with the low-cost alternatives compromising reliability, communication, and quality isn&#;t also a wise choice. 

In Conclusion

We hope this guide will help you decide on the right CNC machining service provider that best fits your business needs, budget, and on-time production demands. And, if you are looking for reliable online CNC machining services, count on us. At Createproto Rapid System Limited, we are offering functional prototypes and low-volume production for automotive, industrial, aerospace, and medical parts and equipment, leveraging our custom CNC prototype machining. From CNC 3,4, and 5-axis machining to CNC turning and milling to EDM- Our exports have got you all covered. 

Call us now or request a quick quote today! and Follow Us on Instagram!

Are you interested in learning more about cnc aluminum machining service? Contact us today to secure an expert consultation!