Small CNC Electronic Parts Thin Aluminum Sheet Milling Machining

CNC Electronic Parts Small Thin Aluminum Sheet Milling Machining:

How To Choose The Processing Method For Aluminum Electronic Parts?

Aluminum is the most common material used in the production of electronic components and is frequently used in industries such as the aerospace, medical and automotive industries. Aluminum parts are strong, have excellent weldability, and are resistant to corrosion, making them essential in manufacturing operations. So what processing method is used when aluminum is manufactured into a perfect part? Usually we need to choose to use 3D printing or CNC machining or aluminum casting service according to the quantity or shape of the parts. Each of these methods has its advantages and disadvantages. A wrong choice can lead to tool damage and high costs, as well as non-functional and unusable parts.

The first is our recommended CNC turning and milling. CNC machining is one of the most common machining methods used to create aluminum prototypes. This machining process relies on computer input to precisely control the machining tool to remove the portion of the aluminum workpiece and leave the desired portion. CNC machining offers good quality, excellent surface finish, repeatability, and compatibility with a wide variety of aluminum alloys. What's more, since the CNC machining process begins with the creation of a 3DCAD model, you can quickly change designs between prototypes without impacting lead times.CNC machining is especially suitable for testing and producing aluminum prototypes. With 4-axis and 5-axis CNC milling machines, you can create complex prototypes that are difficult to handle with other machining methods.

3D printing, another popular way to create aluminum prototypes, uses additive manufacturing techniques to reduce waste. Direct metal laser sintering (DMLS) technology can be used to create 3D printed aluminum prototypes. Here, aluminum powder particles are sintered layer by layer using a high-power laser to form the desired shape.
Like the CNC machining process, 3D printing relies on 3D, CAD models to accurately create aluminum prototypes. Its minimum feature size ranges from 0.25 mm to 0.8 mm, allowing the fabrication of complex geometries with complex internal cross-sections. However, 3D printed aluminum prototypes are not cheap and often require additional surface treatments. 3D printing to create aluminum prototypes is usually more expensive than CNC machining.

Investment casting, also known as investment casting, is a centuries-old casting process used to create aluminum prototypes. Here, aluminum parts are made by pouring molten aluminum into molds made from wax patterns. The process of making molds is expensive since it requires specialized equipment. Therefore, it is not economically feasible to make a mold for one or two prototypes and is more suitable for mass production. Investment casting offers excellent surface finish, tight dimensional tolerances, and compatibility with a wide range of aluminum alloys. Additionally, investment casting has less material waste than CNC machining. The only downside to this process is its size limitation. If you're building bulky aluminum parts, this probably isn't the best choice for you.

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How About The Speed Of Cnc Milling Aluminum?

When milling aluminum, cutting speed (combination of speed and feed rate) also has a significant effect on the results.

Cutting speed for aluminum: vc ~ 100 m/min for high quality high speed steel milling cutters.
Feed for aluminum: fc ~ 0.1 mm per cutting edge. For three cutters, the feed of the milling cutter is 0.3 mm per revolution.
In technical sheets such as metal watch handbooks you can find or calculate guideline values for speeds, dimensions and feeds for different tools and alloys.

The calculation formula of milling cutter speed is as follows:
n = vc / d x pi
n = milling cutter speed in rpm
vc = cutting speed mm/min
d = tool diameter (mm)
pi = number of revolutions (3.14)

The feed rate of the milling cutter is calculated using the following formula:
vf = n * z * fz
vf = feed rate mm / min
n = milling cutter speed in rpm
z = number of cutting edges on the milling cutter
fz = tooth feed in mm / tooth

Example calculation:
3 knives with a 6 mm diameter tool.
Cutting speed vc=100m/min=100*1000mm/min
Milling cutter diameter d = 6 mm
Milling speed n = 5300 rpm
Feed fz = 0.1 mm/rev
-> Feed rate vf = 1600 mm/min

A CNC milling machine is very similar to a conventional milling machine, with the same moving parts, namely the table, cutting head, spindle, and side and cross slides. Instead of levers or cranks to manipulate these moving parts, however, they have a screen inserted into a panel filled with controls and a metal box containing the electrical and electronic components to regulate the operation of the motors used to Performing the same job they did. Lever and crank of an old machine. Among these components is the CNC, which is a computer that is mainly responsible for the movement of the milling machine through the corresponding software. The combination of electronics and drive motors or servo motors enables all possible milling operations.