Advantages and Disadvantages of CNC Aluminum Alloy Parts Processing

Table of Contents:
Chapter 1:   What is CNC Machining
Chapter 2:   Introduction to Aluminum CNC Machining
Chapter 3 :  Why Use Aluminum?
Chapter 4 :  Aluminum VS steel 
Chapter 5 :  Benefits of CNC Aluminum Alloy Parts
Chapter 6 :  What are the most common CNC machining processes for aluminum?
Chapter 7 :  Disadvantages of CNC Aluminum Alloy Material Processing
Chapter 8:  Conclusion
Chapter 9 :  FAQ 

Chapter 1　：　What is CNC Machining?
 CNC machining is the most commonly metal processing production technology. In CNC manufacturing process, cutting tools are used to eject material from solid materials to create parts based on computer-aided design models. You have to get the CNC part out off an oversized piece of material that you are left with what you want. You can chip away at marble until you come up with a masterpiece. This production procedure can be used for the processing of plastics and metals. CNC machining, which also stands for Computer Numerical Control Machining, involves the programming of computer software to issue automatic commands to the functions of manufacturing equipment. Different complex machinery can be operated using this machining method. Another benefit of this process is that it ensures that three-dimensional cutting is completed through a series of commands.
In CNC milling, the part is firmly fixed to the surface and a rotating cutting device is used to remove the material. When turning, the CNC part is firmly fixed to a rotating chuck and then a fixed cutting device is used to remove the material. Different materials that can be produced through CNC machining include brass, aluminum, stainless steel, and nylon.

Chapter 2 :  Introduction to Aluminum CNC Machining
Aluminum is one of the most commonly machined materials because of its excellent mechanical properties. the properties of aluminum include softness, affordability, durability, and resistance to corrosion. Precision machined CNC aluminum parts have become common in recent days, especially in military, medical, aerospace, and industrial engineering. Advanced technology and CNC machines are used to CNC aluminum because they require precision.

the benefit of aluminum is that it is a versatile material that can be used in a variety of fields. It has outstanding features such as being lightweight and durable. Aluminum also requires absolute brilliance to be applied in different fields such as aircraft manufacturing, power generation, and automobile manufacturing. In the automobile production industry, it can be used to make reflectors that are usually used in automotive lamps.

Chapter 3 : Why use aluminum?
CNC aluminum parts are generally cheaper because they can be machined in a short time compared to other metals such as steel. They also do not require additional finishing. Small amounts of zinc, magnesium, copper, and other materials are added to increase strength, as pure aluminum metal is usually quite soft. When exposed to the atmosphere, a thin protective layer forms, making it corrosion-resistant and reducing the chances of rust forming on its surface. It is resistant to chemicals, easy to machine, and has a great deal of strength compared to its weight.

Chapter 4:  Aluminum VS steel 
Aluminum and steel are the most commonly used metal materials in CNC machining. Choosing the right material usually depends on the following five factors:
4.1. Cost ： Mild steel and carbon steel are generally cheaper than aluminum alloys. Stainless steel is more expensive. At the same time, the price of metals changes with global demand and the cost of raw materials, energy and transportation. The durability of the material is also very important when considering cost. If you save money on the material, you may pay more in product life and product quality.
4.2. Corrosion Resistance ： Both aluminum and stainless steel have strong resistance to rust and corrosion. However, stainless steel costs more. Manufacturers or end users need to paint, treat or coat other types of steel to protect the steel, especially if they intend to expose the finished part to the elements. These coatings mean extra weight and cost, and they also need to be re-applied regularly, which adds additional expenses.
4.3. Weight ： Aluminum is two to three times lighter than steel. Almost every company wants to achieve the same or better product performance while using lighter materials. Driven by the "light weighting" trend, manufacturers are beginning to replace many parts that were previously machined from steel with aluminum.
4.4. Strength ： Steel may be heavier than aluminum, but this also makes it more durable. Steel is very strong and does not bend or deform easily under force, heat, or weight. In addition, the surface of aluminum is more susceptible to scratches and dents than steel.
5.5 Machining Capability ：Aluminum is less dense than steel, which means it can be machined three or even four times faster. Aluminum also cools faster than steel; this reduces the time it takes to machine a part (cycle time) and the amount of coolant required.
Aluminum requires much less cutting force than steel. This reduces tool wear and helps the tool stay sharper longer. It also allows aluminum to be CNC machined using smaller, more economical machine tools.

Chapter 5 : Benefits of CNC Aluminum Parts
There are several benefits of CNC machining of aluminum. They include:
5.1. Easy to bend ：  One of the benefits of using CNC machining processes to make aluminum CNC parts is that they can be easily bent. Unlike steel, aluminum materials can be easily turned during machining, as the thickness of this material allows for the use of various forming methods appropriately. Various shapes of aluminum CNC parts are best achieved through pressing and machining.
5.2. Easy Machining ： Another benefit of aluminum CNC machining process is that the material can be easily manufactured through stamping, folding, and drilling. You can use it to form parts of various shapes according to your needs. The energy used to process aluminum is much lower than that used to process steel.
5.3. Low temperature resistance ：Aluminum materials are resistant to low temperatures. We all know how fragile steel is, especially in welding parts or low temperature environments. Aluminum materials can be easily processed at low temperatures compared to steel materials.
5.4. Custom Finishing ：Aluminum can be customized to the customer's requirements after finishing. There are things you can do to give it a perfect custom look. CNC aluminum parts can be plated in various colors according to your requirements. Some of the colors you can try include black, blue, and green.
Aluminum CNC machining will undergo some changes, especially in design and specifications, which gives it the flexibility to quickly transition by initiating new review and approval procedures. It is also possible to go back to the past procedures when you need to, reliably manufacturing ordinary quality in the aluminum removal projects that arise. Some typical aluminum alloys include aluminum 2024, aluminum 5052, aluminum 7075, aluminum 6063 and aluminum 6061.

5.5 High processing accuracy: CNC machining centers have high positioning accuracy and repeat positioning accuracy, which can ensure the dimensional accuracy and form and position tolerance of aluminum alloy parts. Generally, they can reach ±0.01mm or even higher accuracy, meeting the processing needs of various high-precision parts.
5.6 High processing efficiency: CNC machine tools can realize automated processing, and can complete multiple processes after one clamping, reducing manual operation and clamping times, greatly improving processing efficiency. At the same time, the cutting speed and feed speed of CNC machine tools can be optimized according to processing requirements to further improve processing efficiency.
5.7 Stable processing quality: Since CNC processing is automated according to pre-written programs, the influence of human factors is reduced, so the processing quality is stable and the product consistency is good. Whether it is mass production or single-piece processing, the processing quality of parts can be guaranteed.
Strong ability to process complex shapes: CNC aluminum alloy parts processing can realize the processing of aluminum alloy parts of various complex shapes, such as impellers, molds, aviation structural parts, etc. by writing complex processing programs. This is difficult to achieve with traditional processing methods.
5.8 High material utilization rate: CNC processing can reasonably plan the tool path according to the shape and size of the parts to minimize material waste. At the same time, aluminum alloy materials have good cutting performance, and less waste is generated during the processing process, which further improves the material utilization rate.

Chapter 6 :   What are the most common CNC machining processes for aluminum?

CNC milling machines are the most common and versatile way to machine aluminum parts. The machines use a rotating tool. They can efficiently and accurately carve the desired  CNC part from a fixed block of material.

In the 1960s, the traditional milling machines transformed into "machining centers" due to the advent of computer numerical control (CNC) systems, automatic tool changers, and tool rotary devices. These machines are available in 2-axis to 12-axis configurations, but 3-axis to 5-axis configurations are the most common.

CNC metal lathes, or CNC metal turning centers, firmly clamp and rotate the CNC Part while the tool holder holds the cutting tool or drill against the CNC parts. These machines can remove material very accurately and are widely used by manufacturers in a variety of industries.

Typical lathe operations include drilling, shaping, grooving, tapping, threading, and taper machining. CNC metal lathes are rapidly replacing older, more manual production models because of their ease of setup, operation, repeatability, and accuracy.

CNC plasma cutters heat compressed air to extremely high temperatures, creating a "plasma arc" that can melt metal up to 6 inches thick. The sheet of material lies flat on the cutting table, and a computer controls the path of the torch head. The compressed air blows away the hot, molten metal, cutting the material. Plasma cutters are fast, accurate, easy to use, and affordable, and manufacturers in many industries use them.

CNC laser cutters melt, burn, or vaporize material to create a cut edge. Similar to plasma cutters, the sheet of material lies flat on the cutting table, and a computer controls the path of a high-powered laser beam.

Laser cutters use less energy than plasma cutters and are more accurate, especially when cutting thin sheets. However, only the most powerful and expensive laser cutters can cut thick or dense materials.

CNC water cutters use an ultra-high-pressure stream of water ejected through a narrow nozzle to cut the material. Water alone is sufficient to cut soft materials such as wood or rubber. To cut tough materials like metal or stone, operators typically mix an abrasive with water.

Water cutters don’t heat the material like the plasma and laser cutters do. This means the high temperatures won’t scorch, deform, or change the material’s structure. It also helps reduce waste and allows shapes cut from sheets to fit more closely together (or nest)

 Chapter 7 : Disadvantages of CNC aluminum alloy material processing
7.1 High equipment cost: CNC processing equipment is expensive. It costs hundreds of thousands or even millions of yuan to buy an ordinary CNC machining center, and the maintenance and maintenance costs of the equipment are also high, requiring professional technicians to operate and maintain it.
7.2 High programming requirements: CNC processing requires the writing of complex processing programs, and requires high technical level of programmers. Programmers need to have rich knowledge of processing technology and programming experience, and be able to write reasonable processing programs according to the shape, size and processing requirements of the parts. Otherwise, processing errors or low processing efficiency may occur.
7.3 High processing cost: Due to the high cost of CNC processing equipment, high programming requirements, and relatively high prices of aluminum alloy materials, the cost of CNC aluminum alloy parts processing is also high. For some simple parts, it may not be cost-effective to use CNC processing.
7.4 Limited processing efficiency: Although CNC processing has high processing efficiency overall, for some large and complex aluminum alloy parts, the processing time is still long. In addition, if problems such as tool wear and equipment failure occur during the processing, the processing efficiency will also be affected.
7.5 High requirements for materials: The performance of aluminum alloy materials has a great influence on the processing quality. If the hardness, toughness and other indicators of the material do not meet the requirements, it may cause problems such as processing difficulties and increased tool wear. Therefore, when performing CNC aluminum alloy parts processing, it is necessary to select suitable aluminum alloy materials and strictly control the quality of the materials.　　

Chapter 8 : Conclusion
.Aluminum processing is widely used in consumer electronics, from mobile phones, headphones, speakers, watches, to TVs, laptops, and even various smart homes. With the continued growth of the economy, the global demand for electronic communications and other products will continue to grow, which will also promote the expansion of aluminum applications in various segments and gradually develop in the direction of high-end and specialization. Innovate and upgrade aluminum processing technology, pay attention to new trends and new applications of aluminum materials, develop high-precision products, and open up new markets to expand the overall demand for aluminum in consumer electronics.
Thanks to the CNC processing process, the manufacture of aluminum parts has become a breeze. Evaluating CNC machining suppliers is an important part of the purchasing process. In addition to the machine specifications, the supplier's reputation, experience, after-sales support and product warranty, technical support services should also be prioritized. If you have any questions about CNC aluminum machining, please contact our customer service. Our team will provide you and support solution on line as soon as possible.

Chapter 9 : FAQ
9.1 What is a CNC lathe used for?

A CNC lathe can produces symmetrical machine parts, such as shafts and tubes, by machining a CNC part that rotates relative to a fixed cutting tool.

9.2 Can a CNC milling machine effectively process the aluminum?

Yes, a CNC milling machine can machine aluminum according to the specification. Milling machines are particularly well suited for cutting and engraving on aluminum sheets, but are limited when the machining parts are more thicker.

9.3 What are the advantages of a 5-axis CNC machine?

With increased flexibility, 5-axis CNC machines can optimize the production of aluminum parts and minimize associated errors by making complex parts with fewer setups.

9.4  Why is CNC machining the preferred choice for aluminum machining?

CNC machining can produce precise, repeatable machining of aluminum, maintaining the integrity of the material, and providing superior precision and finish.

9.5  How do I choose the right CNC machine for my needs?

Consider project requirements, such as part complexity, required precision, production volume, machine performance, budget constraints, and supplier reliability.