CNC machining is an advanced manufacturing process that subtracts the material from the surface of the workpiece to create a part. It is capable of processing a huge range of materials and Aluminum is probably the most extensively used one.
Aluminum has many appealing thermal and mechanical properties that are ideal for various manufacturing sectors. Due to its excellent machinability, it is relatively easy to perform machining action. Its other properties include lighter weight, durability, malleability, lower material hardness, no magnetism, non-lustrous, corrosion resistance, and greater formability.
It offers an excellent strength-to-weight ratio and sheer variety that enables aluminum to react with other elements to form alloys. These alloys are also mostly acceptable for CNC machining projects. Aluminum alloys in comparison to other lightweight metals (such as magnesium and titanium alloys) are preferred due to obvious reasons that are discussed ahead. These benefits have made aluminum parts common across all industries, though they are particularly favored in the automotive, aerospace, healthcare, and consumer electronics sectors.
This article addresses the key benefits of aluminum CNC machined parts. The reason why it is the most widely used CNC material? Different properties and grades of aluminum will be discussed. Its widespread use across many manufacturing sectors will also be reviewed. Please read on If you want to know about the importance and benefits of aluminum in CNC machining.
Benefits of CNC Machined Aluminum Parts
There are numerous benefits that aluminum offers and provide an added advantage in CNC machining. These properties help to optimize precision processing that ultimately results in optimal part fabrication. The key benefits of CNC machined aluminum parts are discussed below
1). Excellent Strength-to-Weight Ratio
A material having a higher strength-to-weight ratio means it offers excellent strength with comparatively much lower weights. This property of aluminum has exponentially increased its industrial needs over the recent years. Therefore, it finds a lot of applications in many critical industries like defense, aerospace, automotive, etc.
2). Excellent Machinability
Amongst various benefits of aluminum, it has an outstanding ability to be machined easily. That makes it a well-qualified CNC material and it comfortably transforms into the desired shape. It saves many resources and makes faster production possible. Being strong enough to bear the severity of tooling, folding, punching, grinding, and drilling that being applied during CNC machining. And still, it retains its material properties.
3). Custom Finishing
Aluminum is easy to customize to introduce any distinctive characteristics. Any CNC machined aluminum part can have specified surface requirements by applying finishing or its beauty can be cosmetically enhanced. Such as, we can apply any desired color on its surface.
4). Resistant to Low Temperatures
Aluminum is resistant to low temperatures which adds value to it as compared to steel. Steel may prove to be delicate in the welding section or an environment with low temperatures. The low resistant ability of aluminum makes it an outstanding CNC machined material.
5). Environment Friendly
As CNC machining is a subtractive machining process. It creates parts by carving them with the help of different tools. But processing aluminum is environmentally friendly because the waste created can be recycled. That is one of many good reasons that aluminum material is widely used in manufacturing.
CNC machined aluminum parts are the perfect choice for manufacturers who are worried about workpiece waste created due to chipping. It will also help to minimize carbon footprint and encourage environmentally friendly materials to be used.
6). Corrosion Resistant
When any aluminum CNC machined part is exposed in the presence of air then it immediately forms a thin but hard film of aluminum oxide on its surface. Since aluminum has a very high oxygen affinity. Therefore, the formation of aluminum oxidation on the surface of the material enables aluminum corrosion-resistant.
CNC machined aluminum parts are used in various applications where there is a chance for a part to be corrosive. Every grade of aluminum has its corrosion resistance specifications. Like aluminum 6061 offers excellent corrosion resistance as compared to the remaining grades.
7). Tremendous Electrical Conductivity
Due to its tremendous electrical conductivity, CNC machined aluminum parts find their various applications in the electrical sector. Since copper is expensive but its electrical conductivity is superior to aluminum. But Aluminum is still being preferred because it is comparatively cheaper. Cost is the major factor influencing martial selection predominantly.
Applications of CNC Machined Aluminum Parts
As CNC machined aluminum parts offer distinctive properties to choose from as per the requirements and a lot of benefits, as discussed above. Aluminum CNC machined grades are used across different industries for manufacturing a huge variety of parts. Some of the industries that use aluminum due to its added advantages are discussed below
Aerospace Industry
Since aluminum offers an excellent strength-to-weight ratio. That is why it is used to manufacture several aircraft fittings. Because it is roughly a third the weight of steel which enables aircraft to carry more weight and become more fuel-efficient.
Automotive Industry
Aluminum is also extensively used in the automotive industry due to its added properties. Engine radiators, engine cylinder blocks, wheels, bumpers, suspension parts, etc. are few automotive parts manufactured using aluminum.
Electrical Sector
Due to its high electrical conductivities, CNC machined aluminum parts are manufactured to be used in many electrical appliances.
Sports Sector
CNC machined aluminum is used to manufacture different sports equipment such as sports whistles.
Commonly Used Aluminum Grades in CNC Machining
Aluminum has numerous grades. Each grade has its separate features and application. Selecting an optimal grade depends on your intended use as per your part requirements. You can categorize each grade that fulfills specific needs. It will help you to choose the best grade according to specific properties, geometry, and budget.
Some important grades and their properties are discussed as follows
Aluminum 6061
Aluminum 6061 is a precipitation-hardened aluminum alloy. It consists of magnesium and silicon. These elements are included as their major alloying elements. It is amongst the most common aluminum alloys for machining in the 6xxx series. Its versatility in comparison to other grades and good mechanical properties enables it a premium choice by numerous manufacturing sectors.
Aluminum 6061 grade was developed in 1935 and at that time, it was named Alloy 61S. Its properties include good corrosion resistance, excellent weldability, medium fatigue strength, etc.
Due to these properties, 6061 grade is used for general manufacturing, in the automotive industry, aerospace sector, electronics industry, and many more. Specific products manufactured using this outstanding aluminum grade are marine frames, aircraft and truck frames, electronic parts, truck bodies, valves, furniture, fasteners, heat exchangers, etc.
Aluminum 7075
Aluminum 7075 is another magnificent and valuable grade used in CNC machining for highly stressed structural applications. Its chemical composition consists of 5.6–6.1% zinc, 2.1–2.5% magnesium, 1.2–1.6% copper, and less than a half percent of silicon, iron, manganese, titanium, chromium, and other metals. But its primary alloying element is zinc. It also offers excellent mechanical properties such as good ductility, high strength, toughness, and good fatigue resistance.
Due to these machining-friendly properties, aluminum 7075 is highly used in different industries like automotive, aircraft, transportation, and aerospace industries. The products manufactured using this grade are gears, transport vehicle parts, bicycles fuse parts, structural components, weapons, bows, aircraft parts, etc.
Aluminum 2024
Aluminum 2024 is one of the most common aluminum alloys for machining from the 2xxx group. It contains copper as the primary alloying element. This aluminum and copper alloyed material is used in manufacturing such parts that require a high strength-to-weight ratio and good fatigue resistance.
Aluminum 2024 offers many properties like high strength, good workability, good strain resistance, and fatigue resistance. It is stronger than 6061 but less versatile. These properties are preferred in making parts in aerospace, transportation, defense, automotive, and electronics. Car parts, aircraft structures, wings, fuselage, and transport vehicle parts are few examples manufactured using it.
Aluminum 6082
Aluminum 6082 is known as structural alloy and it is very popular in the 6000 series. It falls in the wrought aluminum-magnesium-silicon family and has the highest strength as compared to other alloys of its series. In CNC machining, generally, it is used in plate form to make different products.
6082 grade is made through extrusion and rolling. It contains a predominant quantity of manganese which modulates its grain structure. This grain structure makes aluminum 6082 stronger. But creating thin walled, complex geometrical shapes using 6082 alloy is hard. Because the resulting surface quality is not smoother than other alloys in 6000 series.
This aluminum grade offers excellent corrosion resistance, high machinability, good ductility, and fatigue resistance. It is mostly used in construction and automotive industries for creating parts like trusses, cranes, bridges, trusses, milk churns, ore skips etc.
Conclusion
Aluminum is the most abundant metallic element and the most widely used nonferrous metal, especially in CNC manufacturing. There are a lot of benefits for aluminum production. Due to its distinct properties, numerous aluminum grades find their applications across multiple industries.
As aluminum offers a variety of grades. Each grade has its separate features. That makes aluminum more preferable for CNC machining because these properties are most suited and diversified for CNC manufacturing. That is why it becomes easier to choose the right grade according to the part requirements.
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