Empower your aluminium machining
MACHINING & MACHINERY MATERIAL KNOWLEDGE
MAPAL
Empower your aluminium machining
For many years now , aluminium materials have been becoming more and more prevalent in many industries . This trend continues unabated . While light-weight construction and corresponding materials and structures have always been an important aspect of aerospace , the use of aluminium to reduce weight in automobile manufacturing has increased steadily , and has really taken off now due to electromobility . MAPAL is a leading technology partner for machining aluminium components thanks to its many years of experience designing , producing and applying tools for aluminium machining .
Material knowledge vital to optimal machining processes
Aluminium and aluminium alloys are in principle easy to machine . As the cutting forces are low , high cutting data and in particular long tool life can be achieved with appropriate process planning . However , aluminium alloys have some special features which must be mastered . The geometry of the component and ever-increasing demands on tolerances and process capability pose additional challenges when machining aluminium .
Aluminium alloys can basically be subdivided into the principal categories of cast alloys , wrought alloys and powder-metallurgical alloys , whereby mainly the first two play a role in machining . For cast alloys , various alloy elements and corresponding casting methods are utilised to create the desired properties of a component . When casting , it is important to come as close as possible to the component ’ s final form to simplify mechanical machining . This “ near net shape ” technology has become established
Machining rates of over 90 % are standard in parts production in the aerospace industry . The NeoMill-Alu- QBig indexable insert milling cutter from MAPAL performs outstandingly for volume machining of aluminium .
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MAPAL
in mass production in particular .
When machining casted parts , the silicon content is decisive with regard to the alloy element as it has a powerful effect on wear and tool life . For wrought alloys as well , the desired properties can be brought about by the alloy elements . The silicon content is lower here , though , enabling chipless ductility . Other alloy elements are used here though to achieve good strength and stability as well as fatigue strength . Cold- or warm-worked alloys are the result , which can be processed into wrought material and then be machined .
Solutions for part production and assembly in aerospace
The aerospace industry deploys MAPAL tools both for part machining – i . e . manufacturing components that are assembled to form sections of the fuselage or wing – as well as for the final assembly where the individual sections of the entire aeroplane are put together .
When part machining aluminium parts , the part is frequently machined from solid material . Machining rates of over 90 % call for an efficient volume machining to machine as much raw material in as little time as possible . Powerful tools are key here . The tools must meet a widely variety of requirements in final assembly . Not only is aluminium frequently utilized here , other light-weight materials like titanium and fibrereinforced plastics are also used in one machining step . These so-called stacks are material combinations that pose a particular challenge as the machining characteristics of the combined materials are very different and the tools have to meet their varying requirements .
The aerospace industry has been using aluminium for many years to save weight . Besides the favourable relationship between stability and weight , this material also meets other requirements such as corrosion resistance , fatigue strength and low embrittlement . Therefore , there is high demand for machining solutions for aluminium in part production as well as in final assembly for aeroplanes .
More range with every kilogramme saved
Weight reductions are a primary concern in the development of electric vehicles as well . After all , every kilogramme saved means more range and less CO2 . In mechanical machining for electric vehicles , established processes and tools are very good for producing some of the parts . However , there are inevitably new systems and components in e-vehicles that have to be redeveloped due to their function in terms of geometry and precision and / or material properties . Precision tool makers are called upon to deliver answers when it comes to scaling production volumes in the automotive industry and the habitual
80 PECM Issue 70