Aluminum casting machining is a strategic process. It is widely used by a number of manufacturing industries to produce a variety of products. Unlike before, this process can produce complex parts at low costs.
The process is primarily used to produce aluminum castings that are then machined to form the kind of product you desire. Cast parts sometimes need machining to create features such as sealing surfaces and threaded holes.
It’s a challenge to machine-cast parts, but this can be made simpler by understanding the process. It is also essential to know the characteristics of castings so that you can adapt the machining practices rightly.
The casting process is significantly easy and straightforward; it involves filling a cavity with molten metal. It is then put to rest to cool and solidify into the desired shape. There are different ways to create a cavity, and metal is introduced into the mold in a different way.
To know more about aluminum casting machining, read this blog!
Aluminum Casting Process – What Happens?
First, you cannot go through the aluminum casting machining without undergoing the casting process. In the process, molten aluminum is carefully poured into the mold. It is then cooled off and given time to solidify into the shape you desire.
There are various processes people can use to create the cast, each with its unique advantages and disadvantages. You can choose any depending on the project requirements and the final output of the product you need.
However, die casting, as many would agree, is one of the most widely used aluminum casting processes.It involves injecting the molten metal under high pressure into a mold cavity. Usually, the mold comprises two halves locked together during the casting process.
Aluminum die casting is preferred by manufacturing experts the most, and the reason is simple. It can produce high volume and boasts the ability to produce complex parts with high accuracy and a brilliant surface finish.
Aluminum Castings and Dimension Tolerances When Machining
With castings comes some level of difficulty in the machining process. Most aluminum casting actually has a loose tolerance to machining. Well, you might have investment castings which usually hold higher tolerances but of about a few thousands per inch.
Therefore, the dimensions for the casting may not be as you require. You need machining on the product to achieve the desired dimensions.
Most castings typically have a visible parting line created by a two-part mold used to make the casting. Also, the metal can sometimes leak out between the mold halves during the casting process, leading to a flash on the part, especially when performing aluminum die casting.
This calls for cleaning up the flash using an automated trim press. Depending on how you do it, this can cut into the part and, in other cases, fold over instead of removing it.
All these challenges require extra care during the machining process so that the finished parts meet the required specifications. Most aluminum casting machining experts should be aware of the potential issues that may arise during the process and be ready to adjust for great results.
Aluminum Casting Machining – Insights About the Detailed Process
Once your cast is ready, you take it to the next step – the machining process! It involves removing material from the aluminum casting. This process helps you develop the ideal shape and size for your project.
Aluminum casting machining may involve cutting, grinding, and drilling away the material from the casting to achieve the shape or finish you desire. Machining can be done manually or using a CNC (Computer Numerical Control) machine. This particular machine is precise in cutting and creating shapes based on digital designs.
Aluminum casting machining is a pretty technical process that requires high-quality aluminum parts. Most aluminum machining industries utilize skilled technicians and top-notch equipment to create quality products.
Aluminum Machining Methods
Drilling
Drilling is a common machining method that involves creating holes in aluminum cast parts. With this method, a drill bit is used to remove material from the part, creating the desired hole shape and size.
It is a fast and effective aluminum casting machining method; however, it is not ideal when creating complex shapes or when you intend to remove large amounts of materials.
Milling
You can also perform aluminum casting machining through a process known as milling. It involves removing the parts from the workpiece via a rotating cutting tool.
This tool is strong enough to move in different directions and create various shapes and sizes. It is a perfect aluminum casting machining option if you want to create various shapes.
Turning
If you want to create cylindrical parts, this is the method to use. The method is fast and efficient but unsuitable when removing large amounts of materials and creating complex shapes.
CNC Machining
CNC machining aims to carefully remove and reshape aluminum casts. It is fast, precise, and efficient and helps machines even complex shapes. It utilizes computer-controlled machines to remove material from the casting and get your project’s perfect shape and finish.
Why Should You Consider Aluminum Casting Machining?
Results in High Precision Parts
Taking your aluminum parts through this process ensures you achieve precise and accurate parts. It is a great option when manufacturing products requiring tight tolerances.
It Makes Items More Durable
Even though aluminum is already a durable material, you can make it more durable by using aluminum machining. It is perfect for manufacturing products that need high strength.
It’s Versatile
You can manufacture different kinds of products and even the most complex parts with aluminum casting machining.
What to Look Out for in Machining Cast Aluminum?
It’s pretty easy to machine a cast aluminum alloy. Some features that will ensure you are successful in cast aluminum machining include:
Better Speed – Minimum Roughness
You must aim to use higher cutting speed when machining. This ensures that the processed surface has less roughness since the cutting tool has less time to dig in and leave marks on the surface.
Cutting Geometry
The machining tool’s shape and orientation will determine how the surface will turn out. Using tools with sharp edges and small radii will give you smoother finishes than those with blunt edges and small radii.
Also, the angle at which the cutting tool contacts the workpiece determines the chip formation and the surface’s smoothness.
Cooling
Cooling a workpiece well before machining helps prevent it from deforming and wearing out. This will also help you get a smoother finish on the surface.
Lubrication
Lubrication helps reduce friction and heat during the machining process. This also prevents the tool from wearing out and the workpiece from deforming.
While there are many types of lubricants, selecting one that complements the machine being used, the surface finishes you want to achieve, and the machining operation being performed is only suitable.
Aluminum casting machining is instrumental for producing high-quality, durable, and precisely constructed products. While the process can be challenging, it can be achieved well and more efficiently with the right tools, techniques, and knowledge.
Talk to Sunrise Metal today for all your aluminum casting needs. We employ CNC machines in our process, enabling us to work even on the most complex casts and achieve the desired shape for your project. Request a quote with us today!