Aluminum Alloy

aluminum alloy is a general term for aluminum-based alloys. Because the strength and hardness of aluminum alloy are relatively low, the plasticity is small, the tool wear is small and the thermal conductivity is high, so the cutting temperature is low, so the good machinability of aluminum alloy is an easy-to-process material. In the field of aviation, automobile and machinery, aluminum alloy raw materials are more and more widely used. Due to the high machinability of raw materials, the surface roughness requirements of corresponding parts in the above-mentioned fields are very high. However, the melting point of aluminum alloy is relatively low, and the plasticity increases after the temperature increases. The friction force at the cutting interface is very large under the action of high temperature and high pressure. Easy to stick knives, especially aluminum alloys in annealed state, are not easy to obtain low surface roughness. Therefore, in order to ensure product quality in mechanical processing, there are high requirements for equipment, fixtures, especially tools.

1. Tool Selection for Cutting Aluminum Alloy

cutting tools: according to the hardness and mechanical properties of aluminum alloy raw materials, the materials for cutting cutting tools are generally hard alloy for rough machining and diamond materials for precision machining.

2. Selection of cutting parameters for aluminum alloy

(1) The cutting amount of hard alloy tools can be dry cutting or wet cutting. In the case of precision or ultra-finishing, kerosene can be added for cooling and lubrication, which helps to ensure the quality of processing. The cutting amount for machining is selected as follows:

Cutting speed Vc:Vc = 70~800 m/min. Small brazing tools take a smaller value, generally Vc = 70 ~ 230nr/min; Other types of tools can be more than 300 m/min.

feed f: when turning, f = 0.05-0.3mm/r; F = 0.05~0.25mm/r during milling.

back feeding amount ap: ap = 0.2~3mm when turning; During milling, ap (along the axial direction of the milling cutter) ≤ d(d is the diameter of the milling cutter) and the maximum value does not exceed 12mm, and the milling width does not exceed 0.5d.

(2) The cutting parameters of PCD tools shall be determined according to specific processing conditions. The recommended cutting amount for PCD tool processing aluminum alloy is shown in Table 1.

Table 1 Recommended Cutting Usage for Cutting Aluminum Alloy

tool material type	processing method	recommended cutting amount
Vc/(m/min)	f/(mm/r)	ap/mm
aluminum silicon alloy (w﹤13%)	rough car	300~1500	0.10~0.40	0.01~3.0
fine car	500~2000	0.05~0.20	0.10~1.0
milling	500~3000	0.10~0.30mm/z	0.10~3.0

(3) Cutting Usage of Natural Diamond Tools When super-finishing aluminum alloy materials, the recommended cutting usage of natural diamond tools is shown in Table 2.

Table 2 Recommended Cutting Amount of Natural Diamond Tools

tool material type	processing method	recommended cutting amount
Vc/(m/min)	f/(mm/r)	ap/mm
natural king kong tool	turning	150~4000	0.01~0.04	0.001~0.005

3. Selection of aluminum alloy cutting fluid

The choice of aluminum alloy cutting fluid is very important. It must ensure good lubricity, cooling, filtration and rust resistance. Therefore, the cutting fluid that can be used for aluminum alloy processing is different from ordinary cutting fluids. It is very necessary to choose a suitable cutting fluid. Different cutting fluids should be selected according to different processing conditions and processing accuracy requirements. For high-speed machining can generate a lot of heat, such as high-speed cutting, drilling, etc., if the heat generated cannot be taken away by the cutting fluid in time, the knife sticking phenomenon will occur, and serious debris accumulation will occur, which will seriously affect The machining fineness of the workpiece and the service life of the tool, while the heat can also deform the workpiece, seriously affecting the accuracy of the workpiece. Therefore, the selection of cutting fluid should consider both its own lubricity and its cooling performance. For finishing, it is easy to choose emulsified anti-friction cutting fluid or low-viscosity cutting oil, such as Duso's emulsified cutting fluid soluble AP9001 and cutting oil cut 4201. For semi-finishing and rough machining, low-concentration emulsified friction-reducing cutting fluid or semi-synthetic friction-reducing cutting fluid with good cooling performance can be selected Cutting fluids such as Duso's emulsified cutting fluid soluble AP9005 and semi-synthetic cutting fluid SEMI GL8003.