Aluminum is the most popular and used metal for product designers because it has useful physical properties and is easy to work with. But it is suggested to construct a prototype first and then proceed with the mass production, even if you have the design ready.
But the problem is that many manufacturing techniques are available in the market for making aluminum prototypes. Some of these procedures are additive manufacturing, CNC rapid machining, and low-cost metal forming techniques. Each approach has its pros and cons. If you make the wrong decision, you could end up with parts that can’t work or be used.
Introduction of CNC Aluminium Prototyping
CNC aluminum prototyping is becoming increasingly popular in today’s manufacturing industry.
It is defined as the method of using computer numerical control technology to construct a physical prototype or model of a design. The procedure involves programming a CNC machine to precisely cut and shape an aluminum block based on a 3D computer-aided design (CAD) file.
CNC aluminum prototyping is a quick and inexpensive way to create functional prototypes and test designs before proceeding to mass production. This method is widely employed in the automotive, aerospace, and industrial manufacturing industries.
Why Consider CNC Aluminum Prototyping For Advanced Manufacturing?
Advanced manufacturing refers to integrating technology into traditional manufacturing processes to enhance productivity, reduce waste, and increase efficiency. CNC rapid prototyping is an essential component of advanced manufacturing, allowing manufacturers to produce high-quality prototypes quickly and cost-effectively.
CNC aluminum prototyping is an ideal option for advanced manufacturing, providing various benefits to help manufacturers achieve their goals. Here are some major reasons why you should consider CNC aluminum prototyping for advanced manufacturing:
High Accuracy
CNC machining involves machines that are controlled by computers to produce metal parts with high accuracy. This level of precision is not possible with traditional manufacturing techniques, such as manual machining or casting. CNC aluminum prototyping can produce parts with tolerances as low as 0.001 inches, ensuring that each piece is made to exact specifications.
Speed and Efficiency
One of the significant advantages of CNC rapid prototyping is the speed at which parts can be produced. CNC machines can manufacture parts/prototypes in less time than using traditional manufacturing methods. CNC machines can run continuously without breaks or downtime, allowing faster turnaround times and increased productivity.
Cost-Effective
CNC aluminum prototyping can be more cost-effective than traditional manufacturing methods as they help to build parts fast and accurately. This, in turn, reduces the need for costly rework or scrap. CNC rapid prototyping can also help manufacturers save money by identifying and correcting design issues early in the production process, reducing the need for costly revisions down the line.
Customization
CNC aluminum prototyping allows for the production of custom parts with specific requirements. This customization level is impossible with traditional manufacturing techniques, making CNC rapid prototyping an ideal option for manufacturers looking to produce unique or customized parts.
CNC Aluminum Prototyping Process Explained In Detail
We’ll go through the detailed step-by-step procedure to understand the CNC aluminum prototyping process. Let’s begin with the initial CAD/CAM procedure and will then move toward the completed part.
Step 1: Designing The Part For Production
Even though it may seem obvious. Indeed, a part is only designed with engineering or aesthetic factors in mind. Make sure your product’s features are not too deep, not too tight tolerances, and impossible to manufacture features. Remember that a round tool cannot cut a square inside a corner!
Step 2: Decide The Aluminum Grade To Work With
Choose the grade that suits you best. For heavy parts, use FEA software like Autodesk Fusion 360. Remember your material choice is going to affect all subsequent decisions.
Step 3: Select The Cutting Tools Based On The Aluminum Grade
Use the shortest tool that works with the selected material. You may find it easy to use your long tool instead of ordering a short one. But you’ll regret it when you see the chatter marks on the product.
Before choosing a tool, consider your CNC machine configuration. Tools with many flutes benefit a typical machine with a low RPM but are inefficient and increase cutting forces. A single-flute tool reduces cutting forces and improves chip evacuation on a high-RPM CNC machine.
Step 4: Learn About The Feeds And Speeds
Understanding feeds, and speeds can be difficult for the uninitiated.
Run a tool too slowly, and you risk recutting chips and ruining the tool. Run a tool too quickly, and you’ll shatter your end mill or overload your spindle.
Read the feed and speed guides provided by tool manufacturers carefully, then choose the right one per your needs.
Step 5: Selecting The Right Fixture For Your Part
Choose the appropriate hardware for the piece you are creating. For instance, a vacuum table is ideal for handling large sheets of material. Smaller or atypically shaped components may require a pneumatic or mechanical vise. Complex, multi-sided parts may require a fourth or fifth axis.
Step 6: Selecting The Proper Cooling System Is Important
Chip evacuation requires the right tools and cooling system. Atomized evaporative coolant is a clean way to cool aluminum, but flood coolant, mist oil, and air blast work too. Ensure the chip leaves the cut area quickly, regardless of the method. Poor chip evacuation is the main cause of premature tool failure, so fixing it correctly would be beneficial.
Step 7: Use Uncoated Tools For Miling Aluminum
It may seem obvious to use coated tools but remember that coatings add a thin layer of material over a sharp cutting edge, rounding it over. This might be effective when cutting harder materials, but you risk “galling” when cutting softer grades of aluminum.
Galling occurs when aluminum builds up on the tool’s rounded edge due to poor sharpness. At the cutting edge, it smears aluminum. This speeds up tool wear and reduces milling quality. Sharper tools reduce cutting forces and friction. This improves spindle horsepower utilization, tool life, cycle time, and part quality.
Step 8: Look For Inherent Stresses In The Material
Due to the manufacturing processes, different types of aluminum have different stresses in the material. For instance, internal stresses in extruded 6061 aluminum are higher than in cast MIC-6.
This affects process reliability and finishes tolerances. Cutting stressed material causes “bow” or “potato chipping” warping. Milling one side of a stressed material unevenly twists it. Tools, materials, work holding, and strategies can reduce these stresses.
Endnote
Companies that use aluminum for a huge amount of production should opt for CNC rapid prototyping technique. Enjoy more benefits by working with the right manufacturing company like Sunrise Metal. You can visit our website online or message us anytime for detailed queries or more information.