In CNC -Bearbeitung, why do two shops produce aluminum parts with the same machine—one getting smooth surfaces and long tool life, the other facing frequent tool breaks and rough edges? The answer lies in mastering parameters of CNC processing aluminum. Aluminum’s soft, ductile nature makes it easy to machine, but wrong settings (Z.B., too slow a cutting speed or too deep a cut) waste time, Schadensinstrumente, and ruin parts. Dieser Artikel schlüsselt die auf 6 core parameters, Werkzeugauswahl, cooling strategies, Beispiele für reale Welt, and common mistakes to avoid, helping you achieve flawless aluminum machining.
Why Aluminum CNC Processing Needs Specialized Parameters
Aluminium (and its alloys like 6061-T6, 7075-T6) isn’t like steel or titanium—it has unique traits that demand tailored parameters:
- Geringe Härte: Aluminum’s Brinell hardness (HB 25–100) means it can be cut at high speeds, but softness also causes “built-up edge” (BOGEN)—molten aluminum sticks to the tool, ruining surface finish.
- Hohe thermische Leitfähigkeit: Aluminum transfers heat 5x faster than steel. Without proper cooling, heat damages tools and warps thin-walled parts.
- Duktilität: Aluminum produces long, stringy chips that can clog machines if chip evacuation parameters are off.
These traits mean aluminum needshohe Schneidgeschwindigkeiten, optimized feed rates, Undeffective cooling—parameters that would fail for harder materials.
6 Core Parameters of CNC Processing Aluminum
The following parameters are the “engine” of successful aluminum machining. Each directly impacts efficiency, Qualität, and tool life—use the tables and tips to fine-tune them:
1. Schnittgeschwindigkeit (Vc)
Cutting speed is the speed of the tool’s cutting edge relative to the workpiece (measured in m/min). It’s the most critical parameter for aluminum—too slow causes BUE; too fast overheats tools.
| Werkzeugmaterial | Recommended Cutting Speed (m/my) | Hauptbegründung | Ideal Alloys |
|---|---|---|---|
| Carbid -Werkzeuge | 200–800 | Carbide’s high heat resistance handles aluminum’s fast cutting; TiAlN-coated carbide works best (Reduziert Bue). | – 6061-T6: 300–600 m/min (balanced for speed/quality)- 7075-T6: 200–500 m/min (harder alloy needs slower speed) |
| HSS Tools | 50–150 | HSS can’t handle high heat—slower speeds prevent tool softening. | Alloys for low-precision parts (Z.B., 1100-H14, 3003-H14). |
Für die Spitze: For large workpieces (Z.B., 1m aluminum plates), start at the lower end of the range (300 m/my) Vibration vermeiden; für kleine Teile (Z.B., 10mm brackets), use higher speeds (600–800 m/min) Zeit sparen.
2. Futterrate (Fz & F)
Feed rate has two key metrics:
- Futter pro Zahn (Fz): The distance the tool moves per tooth (mm/Zahn)—controls chip thickness.
- Total Feed Rate (F): The overall tool movement speed (mm/min)—calculated as
F = N × z × Fz(N = spindle speed, z = number of tool teeth).
| Bearbeitungsart | Futter pro Zahn (Fz, mm/Zahn) | Total Feed Rate (F, mm/min) | Schlüsseleinfluss |
|---|---|---|---|
| Rauen | 0.1–0,3 | 500–3.000 | Faster feed removes material quickly; thicker chips reduce BUE. |
| Halbfinish | 0.05–0,2 | 300–1.500 | Balances speed and surface finish; Vermeidet Chip -Anbau. |
| Fertig | 0.02–0,1 | 100–800 | Slow feed creates smooth surfaces (Ra < 1.6 μm); critical for visible parts. |
Beispiel: A carbide end mill (z=4 teeth) machining 6061-T6 at N=5,000 rpm with Fz=0.2 mm/tooth → Total feed rate F = 5,000 × 4 × 0.2 = 4,000 mm/min.
3. Tiefe des Schnitts (Ap)
Depth of cut is the distance the tool penetrates the workpiece (mm). It balances material removal rate and tool load—aluminum’s softness lets you use larger depths than steel.
| Bearbeitungsart | Tiefe des Schnitts (Ap, mm) | Schlüsselziel | Tool Consideration |
|---|---|---|---|
| Rauen | 2–5 | 80–90 % des überschüssigen Materials schnell entfernen; minimize number of passes. | Use strong tools (Z.B., 10mm diameter carbide end mills) to handle load. |
| Halbfinish | 0.5–2 | Glatte raue Oberflächen; Bereiten Sie sich auf die Fertigstellung vor (leave minimal material for final cut). | Medium-sized tools (Z.B., 6mm Durchmesser) balance precision and speed. |
| Fertig | 0.1–0,5 | Achieve final dimensions and surface finish; avoid overcutting. | Scharf, high-precision tools (Z.B., 4mm diameter TiAlN-coated end mills). |
Warnung: For thin-walled aluminum parts (Z.B., 1mm thick enclosures), limit Ap to 0.1–0.3 mm—too deep a cut causes warping.
4. Spindelgeschwindigkeit (N)
Spindelgeschwindigkeit (Drehzahl) is the rotational speed of the tool. It’s tied to cutting speed via the formulaN = (1000 × Vc) / (π × D) (D = tool diameter, mm).
| Werkzeugdurchmesser (D, mm) | Spindelgeschwindigkeit (N, Drehzahl) (for Vc=400 m/min) | Schlüsselnotiz |
|---|---|---|
| 3 | 42,441 | Small tools need high speeds—use dynamic balancing to avoid vibration. |
| 6 | 21,220 | Medium tools: Balance speed and stability; use coolant to reduce heat. |
| 12 | 10,610 | Large tools: Lower speeds prevent tool chatter; check collet tightness. |
| 20 | 6,366 | Extra-large tools: Verwenden Sie langsame Geschwindigkeiten (5,000–8,000 rpm) zur Sicherheit. |
Beispiel für reale Welt: A 6mm carbide tool machining 6061-T6 at Vc=400 m/min → N = (1000×400)/(3.14×6) ≈ 21,220 Drehzahl. This speed removes material fast without overheating.
5. Kühlung & Schmierung
Aluminum’s high thermal conductivity means cooling isn’t optional—it prevents tool damage and BUE.
| Verfahren | Schlüsselmerkmale | Ideale Anwendungen |
|---|---|---|
| Kühlmittel auf Wasserbasis | – High heat dissipation (cools 2x faster than oil).- Niedrige Kosten; leicht zu reinigen. | Hochbändige Bearbeitung (Z.B., automotive aluminum parts); roughing/semi-finishing. |
| Kühlmittel auf Ölbasis | – Reduziert die Reibung (prevents BUE better than water).- Improves surface finish. | Precision finishing (Z.B., visible aluminum enclosures); dünnwandige Teile. |
| Trockenes Schneiden | – No coolant needed; reduces cleanup.- Only works with sharp, beschichtete Werkzeuge. | Small-batch, Teile mit niedriger Präzision (Z.B., Prototypen); avoid for large cuts. |
Für die Spitze: Zum Abschluss, mix 5–10% oil-based lubricant into water-based coolant—it combines heat dissipation with BUE prevention, creating mirror-like surfaces (Ra < 0.8 μm).
6. Werkzeugauswahl (Material & Geometrie)
Even perfect parameters fail with the wrong tool. Aluminum needs tools that resist BUE and cut cleanly.
| Tool Feature | Recommendation for Aluminum | Schlüsselvorteil |
|---|---|---|
| Material | – Carbid (TiAlN or TiCN-coated): Best for high speeds.- Keramik: For extreme speeds (800+ m/my) on soft alloys. | – TiAlN coating repels aluminum (Reduziert Bue).- Ceramic handles heat without wear. |
| Geometrie | – Positive rake angle (10°–20°): Reduziert die Schnittkraft; minimizes BUE.- Scharfe Schneidkanten: Cleanly shears aluminum (avoids tearing).- Wide chip grooves: Prevents chip clogging. | – Positive rake angle makes cutting easier—ideal for soft aluminum.- Sharp edges improve surface finish. |
Vermeiden: HSS tools for high-volume work—they wear out 5x faster than carbide when cutting aluminum at 300+ m/my.
Parameter Table for Common Aluminum Alloys (6061-T6 & 7075-T6)
Use this ready-to-use table to start machining—adjust based on your machine’s capacity and tool specs:
| Parameter | 6061-T6 (Rauen) | 6061-T6 (Fertig) | 7075-T6 (Rauen) | 7075-T6 (Fertig) |
|---|---|---|---|---|
| Schnittgeschwindigkeit (m/my) | 300–600 | 500–800 | 200–500 | 400–700 |
| Futter pro Zahn (mm/Zahn) | 0.1–0,3 | 0.02–0,1 | 0.08–0.25 | 0.01–0,08 |
| Tiefe des Schnitts (mm) | 2–5 | 0.1–0,5 | 1.5–4 | 0.1–0.4 |
| Spindelgeschwindigkeit (Drehzahl) | 3,000–10.000 | 5,000–15,000 | 2,500–8.000 | 4,000–12,000 |
| Kühlmethode | Water-based coolant | Oil-water mix | Water-based coolant | Oil-water mix |
Fall der realen Welt: Machining 6061-T6 Aluminum Enclosures
- Problem: A consumer electronics firm needed 1,000 aluminum enclosures (100mm×50mm×2mm) mit:
- Oberflächenbeschaffung: Ra < 1.6 μm (sichtbar, Keine Kratzer).
- Produktionszeit: < 2 Minuten pro Teil.
- Werkzeugleben: > 500 parts per end mill.
- CNC Solution:
- Werkzeug: 6mm TiAlN-coated carbide end mill (z=4 teeth).
- Parameter: Vc=500 m/min, Fz=0.15 mm/tooth, Ap=0.3 mm (fertig), N=26,535 rpm.
- Kühlung: 8% oil-water mix (prevents BUE, cools tool).
- Ergebnis:
- Oberflächenbeschaffung: Ra=1.2 μm (meets requirement).
- Produktionszeit: 1.8 Minuten pro Teil (beats target).
- Werkzeugleben: 620 parts per end mill (reduces tool costs by 20%).
Common Mistakes & Wie man sie repariert
Even experts mess up aluminum parameters—here’s how to solve 3 frequent issues:
- Built-Up Edge (BOGEN) on Tool
- Ursache: Too slow cutting speed (Vc < 200 m/my) or dry cutting.
- Fix: Increase Vc by 50–100 m/min; add oil-based lubricant to coolant.
- Chatter/Vibration
- Ursache: Too high spindle speed for large tools (Z.B., 20mm tool at 10,000 Drehzahl) or loose clamping.
- Fix: Reduce N by 20–30%; use a stronger clamp (Z.B., hydraulic vise) um das Werkstück zu sichern.
- Warped Thin-Walled Parts
- Ursache: Too deep a cut (Ap > 0.3 mm) or uneven cooling.
- Fix: Limit Ap to 0.1–0.2 mm; use a coolant nozzle directed at the cutting area (ensures even cooling).
Perspektive der Yigu -Technologie
Bei Yigu Technology, Wir sehenparameters of CNC processing aluminum as the key to unlocking aluminum’s full potential. Unsere CNC -Maschinen (YG-6000 series) are optimized for aluminum: they have high-speed spindles (bis zu 24,000 Drehzahl) for fast cutting, and smart coolant systems that auto-adjust flow based on Vc and Ap. We’ve helped clients cut aluminum machining time by 35% and extend tool life by 40%—from automotive part makers to electronics firms. As aluminum use grows in lightweight designs, we’re adding AI parameter optimization to our software—soon, it will auto-suggest settings based on your alloy and part, making flawless machining accessible to everyone.
FAQ
- Q: Can I use the same parameters for 6061-T6 and 7075-T6?A: No—7075-T6 is 30% harder than 6061-T6. Reduce Vc by 20–30% and Fz by 10–20% for 7075-T6 to avoid tool wear. Zum Beispiel, if 6061-T6 uses Vc=500 m/min, 7075-T6 should use Vc=350–400 m/min.
- Q: What’s the best coolant for aluminum finishing?A: A 5–10% oil-water emulsion (Z.B., Mineralöl + Wasser) Funktioniert am besten. It cools like water and lubricates like oil—preventing BUE and creating smooth surfaces. Avoid pure water (causes BUE) or pure oil (schlechte Wärmeableitung).
- Q: How do I calculate spindle speed for a custom tool diameter?A: Verwenden Sie die Formel
N = (1000 × Vc) / (π × D). Zum Beispiel, a 8mm tool machining 6061-T6 at Vc=400 m/min → N = (1000×400)/(3.14×8) ≈ 15,924 Drehzahl. Most CAM software (Z.B., Mastercam) calculates this automatically.