First, aluminum alloy introduction
Aluminum alloys are widely used in engineering structures. Copper, zinc, manganese, silicon, magnesium and other alloying elements are usually used. The processing methods can be divided into two types: deformed aluminum alloy and cast aluminum alloy.The heat treatable reinforced aluminum alloy is a kind of deformed aluminum alloy, which can improve mechanical properties by heat treatment such as quenching and aging, and can be classified into hard aluminum, wrought aluminum, super hard aluminum and special aluminum alloy.
Cast aluminum alloy can be divided into aluminum-silicon alloy, aluminum-copper alloy, aluminum-magnesium alloy, aluminum-zinc alloy and aluminum rare earth alloy according to chemical composition, among which aluminum-silicon alloy has hypereutectic silicon aluminum alloy and eutectic silicon aluminum alloy. Crystalline silicon aluminum alloy, cast aluminum alloy used in the as-cast state.
Second, aluminum alloy high-gloss mirror processing technology and tool selection
Cutting high-gloss aluminum alloy parts (die-cast aluminum parts, high-silicon aluminum parts, forged aluminum parts, aluminum alloy parts, etc.), how to choose the processing technology and tools to improve the surface brightness to achieve a glossy / mirror effect?
1. Processing technology selection: At present, CNC high-light processing technology (milling, turning processing) has been applied in most industrial industries. In recent years, with the development of high-performance, high-precision CNC machine tools and the emergence of excellent tool materials CNC high-gloss processing has made a great breakthrough. It is possible to use milling (car) grinding. The principle of CNC high-light processing is to use special high-light cutting tools on the precision CNC machining equipment, with scientific and reasonable cutting parameters and processes. Glittering machined surface with high brightness mirror effect.
2, tool selection: to achieve high light effect and tool material, machine tool rigidity accuracy, cutting fluid, cutting temperature, cutting speed, material hardness, etc. are related, the most important is the development of diamond tools, diamond tools are almost CNC Standard configuration for the high gloss processing industry. To achieve a high-gloss mirror effect, on the tool selection:
(1) Using a diamond cutter to achieve high-gloss mirror cutting by utilizing the sharpness and non-adhesion of the diamond blade;
(2) By increasing the cutting edge angle of the tool or the passivation of the tool arc, the rotation speed and the feed amount are increased, so-called extrusion processing effect is achieved, and the effect of high-brightness processing can also be achieved;
(3) Use natural single crystal diamond tool processing for bright processing!
Third, OPT super hard diamond tool advantage
1. Performance advantages of OPT superhard diamond tool material:
(1) OPT super hard natural diamond (diamond) cutter with hardness of HV9000-10000 is the hardest material found in nature. Natural diamond cutter can keep the size stable for a long time during cutting, so it has a long use. life. The tool made of natural diamond has a circular arc portion under the microscope of 400 times and is suitable for processing materials such as gold, silver, copper, aluminum (aluminum alloy), zinc (zinc alloy), and acrylic (plexiglass). The roughness of expression can reach Ra (0.01-0.025) μm;
(2) OPT super-hard artificial single crystal diamond (diamond) knives, artificial single crystal diamonds are slightly inferior to natural diamonds, but their performance is comparable to natural diamonds, and the price is relatively lower than natural diamonds;
(3) OPT superhard synthetic polycrystalline diamond (PCD) cutter is a polycrystalline material obtained by solvent-polymerizing diamond micropowder under high temperature and high pressure. Its hardness is lower than that of natural diamond (about HV8000), PCD cutter and carbide cutter Compared with the hardness, the hardness is 3-4 times higher; the wear resistance and the life is 50-100 times higher; the cutting speed can be increased by 5-20 times; the roughness can reach Ra0.05μm-Ra0.4μm, and the brightness is slightly lower than the natural diamond. Cutting tools and single crystal diamond tools are relatively low in cost, high in cutting efficiency and stable in machining accuracy.
2. Types of OPT superhard diamond tools:
Turning, milling, drilling and reaming are common methods for cutting aluminum alloys. OPT superhards introduce a variety of tools for different cutting methods, such as diamond blades, diamond turning tools, diamond milling cutters, diamond milling inserts, Diamond chamfering knives, diamond contour knives, diamond drills, diamond reamers, diamond boring tools, etc., can also be customized according to user requirements for non-standard tool customization, and the tools designed by Valin Superhard, or other technical improvements The project is freely adjusted by OPT for free adjustment until the customer is satisfied!
Taking aluminum alloy high-gloss milling as an example, the precautions for processing aluminum alloy with OPT super-hard diamond tool are
summarized:
1. The influence of cutting amount on processing quality. Under normal circumstances, OPT super-hard diamond cutters, when milling aluminum alloy materials, as long as the system rigidity allows, the higher the line speed, the better;2. The influence of machine tool clearance. The moving parts of all machine tools have clearances, and the gap between the new lathes is small when leaving the factory; the system rigidity of the machine tool is good, and the longer the lathe is used, the larger the gap will be;
3. Balance and stability.
(1) If the aluminum piece has a large diameter and its own dynamic balance is poor, the dynamic balance of the clamp is required to be appropriate.
(2) The unevenness of the machining allowance induces vibration, which has an adverse effect on the processing effect of the aluminum parts. Generally speaking, the process is divided into coarse and fine two-step processing, which is better than the one-shot machining of the blank.
