What are the key factors to consider in designing and building ...

What are the key factors to consider in designing and building CNC fixtures for machining aluminum extrusions

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What are the key factors to consider in designing and building CNC fixtures for machining aluminum extrusions

1. Can fixture be designed to eliminate human interaction that may affect end product quality

2. Critical dimensions

3. Surface importance/Class A surface requirements

4. End use of the extruded aluminum product

5. Tolerance requirements

6. Gauging requirements for checking fabricated aluminum extrusion

7. Can fixture take care of variances in aluminum extrusion without affecting machining quality.

What are the key factors to consider in designing and building CNC fixtures for machining aluminum extrusions

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CNC Aluminum Extrusion: The Ultimate FAQ Guide

I know you&#;re probably looking for more information about CNC aluminum extrusion.

A reason this guide will answer all your questions about CNC aluminum extrusion.

Keep reading to learn more.

What Is CNC Aluminum Extrusion?

This is a fully automated process, which is accurate and guarantees tolerances as low as +/-0.02mm.

CNC stands for Computer Numerical Control. The CNC machine operates on a computer program.

A CNC Machine

 Aluminum is the most common material used in CNC machines. It has thermal and mechanical properties, which make it suitable for CNC machining.

Aluminum is highly millable, which makes use of the CNC easy and effective.

What Are The Benefits Of CNC Aluminum Extrusion?

CNC Aluminium Extrusion has several benefits. They include;

• Production of Aluminium Extrusion products that are of superior quality.
• The CNC Aluminium Extrusion process is automated and has other secondary machining sectors. This reduces labour requirements, thereby reducing cost and human errors.
• Typically, the CNC machine processes are centralized in a particular location. This reduces the time required as well as simplifies the procedure as it requires only one vendor.
• Also, the CNC Aluminium Extrusion process is automated and primarily continuous. This leads to an increase in output.
• It is safer as all the procedures are from the command centre controlled by skilled operators. If any corrective measures are needed, then the line can be stopped and restarted if necessary.

A CNC Aluminium Router

Which Shapes And Profile Can You Make From CNC Aluminum Extrusion?

Below are the common shapes and profile you can manufacture from CNC aluminum extrusion.

T- slot

The T-slot is made for structures that have three dimensions made from extruded aluminum parts.

With the T-slot, each piece of extruded aluminum has one or multiple T-shaped slots that can fit attachment with a similarly shaped end.

This enables you to connect complex parts without needing to weld or clamp them.

T Slot CNC Aluminium Extrusion

Channel

There are two types of extruded Aluminium channels; aluminum C channel, aluminum U channel, aluminum F channel, aluminum J channel, aluminum H channel, and aluminum T channel.

They have inner radius corners, which are best suited for structural applications that require greater strength.

C Channel

It is commonly used for fabrication projects that require resistance to corrosion and is lightweight.

It can be used to make support beams, frameworks, braces, among others.

U Channel Aluminium Extrusion

Complex Construction Profiles

The complex construction profile has low net weight and high strength. They are also highly thermo-efficient.

The complex construction profile is bendable and has personal stiffness.

Are There Limitations Of CNC Aluminum Extrusion?

There are several benefits of CNC Aluminium Extrusion.

However, with the added benefits such as accuracy and precision, there are some disadvantages.

These limitations include;

• Increase in cost; CNC Aluminium Extrusion costs more than other extrusion methods. The high price is contributed to by several factors, including the cost of the CNC machine, among others.
• Size constraints of CNC Aluminium Extrusion; while the CNC milling machine can produce extruded aluminum of a variety of sizes, the device is more efficient with large pieces.
• The size of the piece produced can be influenced by the size of the enclosure and the tool.
• The operator error; because the machine is automated, the operator controls the accuracy of the CNC Aluminium Extrusion process.

How Can You Test Quality Of CNC Aluminum Extrusion?

There are several tests that can be carried out to ascertain the quality of the CNC extruded aluminum. These tests are grouped in the following tests.

The Extrusion Performance Tests

Tensile Test

The tensile test is carried out to ensure that the pieces produced do not adhere to the set industry limits.

These limits are on a particular parameter, such as yield tensile strength, ultimate tensile strength, and elongation.

Weldability Test

Welding is commonly carried out on extruded Aluminium products to create new products. It is therefore essential to ensure that the product passes the set specifications.

Workability Test

This test is carried out to ensure that pieces produced can still undergo other procedures such as grazing, threading, machining, and grinding, among others.

Corrosion Resistance

There are two types of tests done to determine corrosion resistance: the salt spray test and the humidity resistance test.

Flammability Testing

This process is done for Aluminium Extrusion that is coated with flammable material.

The Hardness Test

This is a test done to ascertain that the extruded aluminum has achieved its specified hardness.

Hardness helps determine the Aluminium Extrusions&#; suitability for their various applications.

Resistance To Weathering Test

This test doesn&#;t ensure that the extruded Aluminium fan be used for outdoor operations.

There are several types of tests that can be conducted to verify aluminum suitability.

The most common procedures are outdoor exposure and Accelerated exposure.

Abrasion Resistance

This test is done to check if the abrasion coefficient value of coating is not below the set standards.

Chemical Resistance

This test is conducted to ensure that the products can resist standard chemical decomposition. There are several types of tests performed.

They include nitric acid resistance, window cleaner resistance, muriatic resistance, mortar resistance, and detergent resistance.

Extrusion Visual Test

Visual Defects Test

The material should be checked for visible defects such as uneven wall thickness, sharp edges, lumps, Black specks, surface cracking, internal cracking, warps, surface lines, and uneven coatings.

It is essential that these parameters are set by the customer to work as a guide for the supplier as well as the inspector.

In case you are not very sure of the visual effects to add, it could be helpful if your supplier could show a sample for comparison in determining if the product has passed or failed.

Color And Glossiness Inspection

There are numerous methods that can be used to verify the color and glossiness of extruded aluminum profile.

The simplest method involves comparing the finished products against approved samples or with recommended values on the Pantone color chart.

In cases where the buyer&#;s needs are more demanding, then a spectrophotometer and a gloss meter can be used.

Inspecting the color and glossiness of the CNC extruded aluminum is done under certain lighting conditions to enhance accuracy.

Dimensional Inspection

There are several parameters that length, holes, wall thickness, sizes, width, curvature, and mitered joints.

It is essential to consider these parameters in the aerospace, medical, automotive industry.

It is extremely vital to ensure that the parameters adhere to set industry standard tolerances.

Coating And Finishing Inspection

This test helps determine the quality of coating and finishing that is carried out on CNC extruded Aluminium profiles.

Some of the parameters inspected are the coatings thickness, edge, evenness, quality and surface reflective, and smoothness.

Weight And Density Inspection

This ascertains that extrude aluminum does not exceed the limits set for industrial use on density and weight.

CNC Aluminum extrusions are preferred because of their lightweight; therefore, it is essential that these properties are inspected.

Extrusion Visual Test Is A Check That Can  Identify Areas That Need Correction

Extrusion Materials Inspection

Aluminum Alloy Inspection

This ensures that the correct kind of aluminum billets are used for the extrusions process.

Alloys such as , , , and A use standards set by the International Alloy Designation System used for aluminum extrusions.

Extrusion Dye inspection

Extrusion dyes are essential for meeting the designs and specifications of the buyer. Extrusion dyes can be tested in various ways. The test areas include; hardness, clearance, bearing squareness, and length and dimensional measurements.

What Determined CNC Aluminum Extrusion Cost?

There are several factors that determine the cost of CNC Aluminium Extrusion. These factors include:

• Cost of a CNC machine.
• Size of the CNC extruded aluminum.
• Type of fabrication done on the extruded aluminum.
• Size of the extruded aluminum is required.
• Custom features also add to the overall cost.

Is There Recommended Tolerance Of CNC Aluminum Extrusion?.

Yes. The standard tolerance limit for CNC Aluminium Extrusion is around 0.127mm, which is +/-0.005.

The CNC Aluminium extrusion is a fully automated process that is accurate and guarantees tolerances as low as +/-0.02mm.

CNC Aluminum extrusion is not a product but a function of extruded aluminum.

If you want to learn more, please visit our website Aluminum Extrusion CNC.

Is There Recommended Thickness of CNC Aluminum Extrusion?

Yes, the recommended thickness is 0.8. Feasible thickness is about 0.5.

Therefore the piece produced should have a thickness ranging from 0.8 to 0.5.

Suppose the walls of the extruded aluminum are too thin.

In that case, it leads to breaking or warping the walls due to unwanted vibrations from the CNC machining.

How Does CNC Aluminum Extrusion Process Work?

The CNC operates in a computer program.  The complex Aluminium Extrusion procedures are handled by the machine without human input.

The automated system prevents variations intolerance in the components produced.

Short and Long bed lathes are used to enhance precision in CNC machining.

CNC machining has indexing features that allow 4 axis rotation so that the extruded aluminum can be latched on all of its planes in a single or two settings.

It also provides for procedures such as drilling, milling, punching, welding, cutting, and bending.

Which Surface Finishes Can You Apply After CNC Aluminum Extrusion?

Surface finishes not only improve the aesthetics of the CNC aluminum extrusions, but also improves its durability.

Discussed below are the common surface finishes for the CNC aluminum extrusions.

Electrophoresis

Electrophoresis involves a number of stages to be carried out before the actual electroplating takes place.

These stages are the cleaning stage, after which comes the phosphate conversion coating.

The phosphate conversion coating is done to improve the Aluminium resistance to corrosion.

After this, electropainting is done. This is then followed by the last stage, the oven curing stage.

An Extrusion That Has Undergone Electrophoresis

Powder Coating

Powder coating involves applying free-floating powder on a surface.

Powder coating creates a thin hard finish which is better than paint.

Its electrostatic step increases coverage and efficiency.

It also has an even spread.

Powder Coated Aluminium Extrsuion

Painting

Painting involves applying liquid paint on the extruded aluminum.

The traditional process of applying a liquid paint to a metal product for finishing. It is economical and straightforward to execute.

Anodized

This is an electrochemical procedure that involves the conversion of metallic surfaces into anodic oxide, long-lasting, aesthetic, corrosion-resistant finish.

Polyvinylidene Fluoride Coating

PVDF coatings are primarily used in industrial and commercial coatings.

It is a fluoropolymer resin that is very stable and inert, which enhances the Aluminium resistance to weathering.

PVDF Coated Aluminium used On A Building

How Long Does A Complete CNC Aluminum Extrusion Process Take?

The CNC Aluminum extrusion goes through CNC machining, which is an automated procedure that can continue working without a break.

This increases productivity as well as efficiency without human interruptions. It takes a few days for the process to be completed.

Can You Weld CNC Aluminum Extruded Parts?

Yes, CNC Aluminum extruded parts can be welded. Welding of extruded aluminum needs specific equipment and skills.

The alloy series is the easiest alloy to weld.

What Causes Deformation During CNC Aluminum Extrusion?

The Aluminum alloys have high thermal expansion. They are also characterized by low hardness.

The combination of these two features leads to deformation, especially on delicate parts.

Which Material Grade Is Best For CNC Aluminum Extrusion Process?

It depends on the product you wish to extrude

There are many aluminum grades available. They include;

Alloy Series:

The series is ninety-nine percent aluminum and has excellent workability. It is very soft and malleable.

These properties make it suitable for the piece that requires a lot of forming as it slowly hardens during formation.

Besides, the series is the most weldable aluminum alloy in the market.

Alloy Series:

The alloy series are mixed with copper. This series can be hardened by precipitation.

It contains about 2-10 percent of copper with minor additional elements.

Besides, it has the most vigorous heat treatment.

It can be used to make gears, electrodes, fillers, compressor rings, among others.

Alloy Series:

The alloy series are mixed with manganese.

They have high strength.

This series exhibits medium resistance to atmospheric and chemical agents.

This series has increased formability compared to pure aluminum.

They can, however, not be heat treated. It can be used to make cooking utensils, food processing, and handling components, among other uses.

Alloy Series:

The alloy series is mixed with magnesium. It has increased corrosion resistance which makes it best suited for marine applications.

The alloy series also include manganese.

Alloy Series:

The Alloy series is mixed with silicon and magnesium. They can be hardened using precipitation.

They are highly weldable and have high machining.

Aluminum :

The Aluminum is widely used in the aerospace industry.

Its high strength, high thermal conductivity, and low density are some of the features that make it very popular. It is also used in mold tool manufacturing.

Alloy Suitable For Industrial Application

What Are The Unique Features Of the CNC Aluminum Profile?

Some of the unique features of the CNC Aluminum profile. They include;

• Resistance to corrosion: Aluminum is highly resistant to corrosion in many environmental conditions.
  Even in chemical systems, petrochemicals, air, and water aluminum exhibit superior corrosion resistance.
• Good conductivity: Aluminum profiles have excellent electrical conductivity.
• High thermal conductivity: Aluminum&#;s high thermal conductivity is almost as tall as coppers.
  This makes it beneficial for use in heating appliances and other heat-related products.
• Non-ferromagnetic: This feature makes it essential when it comes to electrical and electronic products.
  They do not combust spontaneously, which is a requirement when handling explosive or flammable materials.
• Machinability: Aluminum profile has excellent workability.
• Formability: can easily be molded.
• Recyclability: recycled aluminum has no significant difference from the original aluminum.

Unique Features Of The CNC Aluminium Extrusion Makes It Marketable

Does CNC Aluminum Profile Require Heat Treatment?

Yes, Heat treatment is required out on the CNC Aluminum Profile.

The process is not compulsory, but it helps improve several features of the extruded aluminum.

The heat treatment is carried out as a finishing step after formation.

It can also be carried out after CNC Aluminum Extrusion to increase the material&#;s hardness.

How Can You Reduce the Cost Of CNC Aluminum Extrusions?

Ideally, the cost of any product should be economical. Consequently, there are various ways to make a CNC aluminum extrusion affordable. This include;

Using Rounded Internal Corners

Changing the internal corner design of the extruded aluminum helps reduce the overall cost of the process.

This is because sharp 90-degree corners need the machine to halt for the part to be rotated before proceeding.

This increases the production time, which will also increase the cost of CNC Aluminum Extrusion.

Avoiding Deep Pockets

Deep pockets are required to remove more material in order to create them. This process is not only time-consuming.

It requires additional tools to execute the design. This impacts negatively on the cost of CNC Aluminum Extrusion.

Reducing The Use Of Tight Tolerances

The tighter the tolerance, the higher the cost of production.

This is because it requires additional manual inspection and hikes the machining time.

Tighter tolerances are difficult to attain on the internal surfaces because burrs form on cavities and other machining holes.

Another procedure, therefore, has to carry out to get rid of the burrs called deburring.

This process is carried out manually and is time-consuming, which drives up the cost of CNC Aluminum Extrusion.

Expanding The Thin Walls

Thin walls are fragile and therefore require more time to make.

Low setting depths are used multiple times to reduce the chances of errors occurring. Holes placement and close to the edge are some of the common causes of thin walls.

How Can You Enhance Dimension Stability Of CNC Aluminum Profiles?

Enhancing dimension stability gurantees a more robust CNC aluminum profile.

There are several ways in which you can enhance the dimension stability of CNC Aluminum profiles. They include;

Removing The Internal Stress Of The Material

This is achieved by aging artificially and naturally as well as treatment using vibration.

This is followed by removing the excess parts beforehand.

After one to two hours of natural aging, the process helps remove deformation resulting from internal stress.

Improving The Work Piece&#;s Clamping Method

Using suction cups for evenly distributing the clamping force across the thin plate and filling inside the workpiece to improve rigidity helps to improve the machine&#;s accuracy.

Increasing The Tool&#;s Ability To Cut

Factors such as the geometric and the material of the tool significantly impact its cutting force and heat.

The correct tool helps increase dimensional stability.

Select An Appropriate Machining Process

The high-speed CNC machining procedure involves rough &#; semi-finish &#; clear corner &#; finishing.

Increasing the number of semi-finishing machines and maintaining an even allowance is required for parts that need high precision.

Select The Suitable Feed And Spindle Speed And Cutting Depth

This is done by ensuring that there is uniformity in machining for the front and end and multi-layering for cavities of the workpiece.

Another step is to ensure that drilling is followed by milling for parts with a cavity.

What Is The Minimum Order Quantity For CNC Aluminum Profiles?

Typically, most manufucturers and sellers have no minimum order quantity for their CNC aluminum extrusions.

However, some manufucturers set the minimum order quantity within a range of 500 to pounds.

What Is The Ideal Temper For CNC Aluminum Profiles?

There are different types of tempering processes. The ideal temper differs with the grade of CNC Aluminium Profile used. The most commonly found tempers include;

• T3 &#; The T3 process involves using a treated solution that is heated. This is followed by cold working for increasing strength.
• T4 &#; The T4 temper is achieved by heating in a solution followed by treatment then naturally aged.
• T5 &#; The T5 temper is first cooled then aged in an oven.
• T6 &#; The T6 temper is heated in a solution then aged in an oven.

For any question or inquiry about CNC aluminum extrusion, contact us now.

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