Aluminum CNC Machining: A Definitive Guide!

Aluminum is a versatile element used in various industries. From aerospace to automobiles, this metal has a stronghold. But have you considered what helps manufacturers make complex shapes with aluminum? You bet it right—that’s aluminum CNC machining.

 

CNC machining allows manufacturers to cut and shape aluminum with precision. As a result, they make complex aluminum parts and components. Aluminum is undoubtedly a very popular material. However, people don’t understand CNC machining. This guide will provide an in-depth explanation of this topic.

 

Overview of CNC Machining of Aluminum

CNC machining is a manufacturing process that relies on a computerized system. CNC itself stands for Numerical Control System. This manufacturing process is quick and offers exact output due to CNC. Machines used in these processes are called CNC machines.

 

As I said above, aluminum is one of the most used materials in different industries. Its excellent machinability, strength, and inexpensiveness make it stand out. Manufacturers use this material and machine it through a CNC system. As a result, various parts and products are made that are 100% similar to what the manufacturer wants.

 

CNC machining has contributed to the extensive usability of this material. For example, the aerospace industry uses aluminum to make different parts. The reason is that aluminum is a lightweight material. But those parts have complex, intricate designs. So, the CNC machine helps manufacturers make those complex parts.

 

Without CNC machining, aluminum’s usability would have been very meager. Let’s briefly overview how CNC machining of aluminum works. First, the operator designs the product he wants to get. Once this is done, the design is changed into the programmed instruction in coded form. 

 

This coded instruction is fed to the computerized system. The workpiece (aluminum material) is placed on the CNC machine’s work table. The operator switches on the system. As a result, the CNC machine cutting tool starts to follow the coded instructions. They cut and shape the workpiece (aluminum material) as per the coded instructions.

 

Ultimately, the manufacturer gets the final output that is similar to his initial design. This is how CNC machining of aluminum works. Remember, this computerized process gives 100% precision with breakneck speed. Moreover, you can have excellent repeatability, which further enhances its scope. Remember, this manufacturing process is prevalent.

 

Common Aluminum CNC Machining Techniques

As I said above, the CNC machining topic is very comprehensive. Different techniques are used in this manufacturing process. Each method differs from others in terms of its workings and outputs. It won’t be wrong to say that each method is distinct. Let’s dive down and discuss each technique.

 

1- CNC Milling

 

In CNC milling, the workpiece remains stationary. The cutting tools move and cut the aluminum material (workpiece). CNC milling machines are used in this process. Different types of these machines are available, varying in their number of axes. 

 

Some machines have three axes and can only make simple shapes. On the other hand, some CNC milling machines have more than five or six axes and are suitable for making complex shapes. This machining technique helps make engine parts, surgical tools, and rapid prototyping.

 

2- CNC Drilling

 

CNC drilling is a straightforward process of making holes in the workpiece (Aluminum). But you may say these holes can be made without using CNC machining. You are right, but sometimes, manufacturing requires a hole with precision. The accuracy decreases when you use conventional methods for making holes. 

 

Keep in mind that aluminum is a solid material. Therefore, CNC drilling machines are used for this purpose. These machines are exact and follow computerized instructions. The size and depth of the hole are essential for a complex manufacturing process. Minor errors could result in the incompatibility of components in that hole. 

 

CNC drilling works best in such cases. It controls the sizes and depth of the hole and ensures accuracy. Thus, these holes can be manufactured quickly to fit bold or any component assembly. Moreover, the CNC drilling machines offer rapid output. Manufacturing can put multiple holes in aluminum material in no time.

 

3- CNC Turning

 

Turning machines are an excellent way to easily make any complex shape. In this method, the workpiece (Aluminum) is loaded on the chuck and allowed to spin. During this spinning, the single-cutting tools move along the workpiece. They remove the parts from the workpiece and shape it as per instructions.

 

Keep in mind that this whole process is based on a computerized system. So, the workpiece is cut in a way that meets the needs of manufacturers. The CNC turning method is used to make different products with diverse shapes. Examples include cylindrical, grooves, threads, and so on. CNC turning of aluminum is cost-effective and offers a quick turnaround.

 

Benefits of Using Aluminum for CNC Machined Parts

From all the above, you have gotten the idea that CNC machining of aluminum material is very trendy. Right? But the question is, what makes this material go-to for CNC machining? Let’s dig into and explore the details.

 

1- Strength & Durability

 

Aluminum is a super strong material with excellent durability. It means during the machining it does not break. Moreover, the parts made with aluminum can bear harsh usage. There is no point in using material in CNC machining if it is not strong enough.  The parts and components that consist of aluminum last for years without deteriorating. That’s why manufacturers consider it suitable for CNC machining.

 

2- Corrosion Resistance and Longevity

 

What I love about aluminum is that it offers an excellent fight against corrosion. Let me explain how. When in contact with oxygen, aluminum forms an oxide layer called an aluminum oxide coating. This layer shields the aluminum from corrosion. Due to this corrosion resistance, this material stays in good shape for an extended duration. This feature further enhances its scope for CNC machining.

 

3- Lightweight & Machinability

 

Aluminum is lightweight, so its parts are suitable for aerospace and automobiles. These parts reduce fuel confusion in automobiles. Moreover, their lightweight capabilities enhance the aerodynamics of airplanes. Furthermore, aluminum is very easy to machine. The reason is that it is brittle. So, cutting and shaping through the machine is safe.

 

4- Surface Finish & Versatility

 

The aluminum material is very versatile. You can get different aluminum alloys that give you more specific properties. Imagine you need extreme strength. In such a case, you can use an aluminum alloy with magnesium, copper, and chromium (7075 aluminum).  Similarly, different Aluminum alloys are available that have unique properties. 

 

Moreover, the manufacturer uses it to make different shapes. No matter how complex the shape is, aluminum never disappoints. Surface finishing is another aspect that makes aluminum suitable for CNC machining. The CNC-machined parts of aluminum don’t need the additional process of surface fishing. Their cutting during machining gives them surface fishing.

 

5- Cost & Affordability

 

Aluminum is an inexpensive material. Its use in making different parts and components does not add much cost. Moreover, their CNC machines parts of this material area are also less costly. So manufacturers can easily use those parts to complete any project. Conversely, other materials that offer properties similar to aluminum are expensive. 

 

Using them externally in CNC machining is cost-friendly. Aluminum offers properties similar to premium titanium material. I don’t say aluminum is as good as titanium. But when you look at the prices of both materials, you tend to be inclined towards aluminum. It is a value-for-money material!

 

Which Grade of Aluminum is Suitable for CNC Machining?

 

As I said earlier, aluminum has many alloys. Manufacturers use different alloy elements to achieve desired properties. Due to these alloys, aluminum has many varying grades. Each has unique properties and specific purposes. Let’s investigate the details of those aluminum grades suitable for CNC machining.

 

• 1000 Series

 

Aluminum 1xxx alloy contains the purest aluminum and at least 99% by weight. Without specific alloying elements, these are almost all pure aluminum. For example, aluminum 1199 contains 99.99% aluminum by weight and makes aluminum foil. These are the softest grades but have excellent corrosion resistance. Manufacturers use it for CNC machining to create products for the food industry.

 

• 2000 series

 

Copper is the primary alloying element in the 2000 series of aluminum. These grades of aluminum can be precipitation-hardened. Due to this, they are almost as strong as steel. Are you confused about the precipitation hardening? It is the process of heating the metal to a specific temperature. 

 

This heating improves aluminum’s yield strength. Due to the presence of copper, the 2xxx aluminum grade has low corrosion resistance. Aluminum 2024 also contains manganese and magnesium, used in aerospace components. The CNC machine has a series of alloys and makes heavy-duty products.

 

• 3000 Series

 

Grade 3xxx aluminum contains manganese as its most important additional element. These aluminum alloys can also be work-hardened. Aluminum 3004 also contains magnesium, which is used for making beverage cans. These grades offer excellent machinability and corrosion resistance. Due to the machine’s friendliness, the manufacturer uses it for CNC machining. Generally, its products are used in homes for cookware.

 

• 4000 Series

 

Silicon is the primary alloying element in 4000 series aluminum. Silicon lowers the melting point of Aluminum 4xxx grade. Aluminum 4043 is used as a covered electrode material for welding. In buildings, 6000 series aluminum alloys and aluminum 4047 are used as plates and cladding. These grades of aluminum are also under CNC machining. Manufacturers make products that remain under low temperatures. The reason is that they have low melting points.

 

• 5000 Series

 

Magnesium is the primary alloying element in the 5000 series. These grades have the best corrosion resistance and are very durable. Due to this, they are usually used in marine applications. Parts used in marine applications remain in contact with salty water. So, their excellent corrosion resistance keeps them in good shape for a long time. For example, aluminum 5083 is an alloy often used in ship parts. CNC machining of these grades also produces marine industry products.

 

• 6000 Series

 

As said above, both magnesium and silicon make many aluminum alloys. The combination of these elements is used to create the 6000 series. This series of Aluminum is not very strong. Therefore, it is precipitation-hardened. However, it has good corrosion resistance, machinability, and weldability. This aluminum series is standard in the automobile industry.

 

• 7000 Series

 

These aluminum alloys mainly consist of zinc. However, some alloys in this series can consist of copper, chromium, and magnesium. What I don’t like about these alloys is that they are not very corrosion-resistant, and parts made with them are not very long-lasting.

 

However, their strength and robustness make them stand out. Because of its high strength, class 7000 is usually used in aerospace applications. Let me give you an example. 7075 is a common brand of this series. Its corrosion resistance is lower than other alloys, but its strength and hardness are excellent. 

 

• 8000 Series

 

In the above section, I mentioned seven different series. But some alloys still don’t fit in any of those categories. So, these unique alloys fall in the 8000 series. These alloys can include many other elements, including iron and lithium. For example, 8176 aluminum contains 0.6% iron and 0.1% silicon (by weight) used to make wires.

 

Applications of CNC Machining of Aluminum

 

In the above section, we understood the different aspects of CNC machining of aluminum materials. I hope you have a firm grasp and are not confused. I still want you to keep reading. Why? I’m going to mention a critical application of CNC-based machining. It will help you understand how this manufacturing process is used.

 

1- Aerospace Industry

 

Aluminum is lightweight. So manufacturing is used to make different components of airplanes. It enhances the aerodynamics. Moreover, the excellent strength of this material further makes it ideal for this industry. Here is the list of parts that are made by CNC machining of aluminum materials:

 

• Wings
• Brackets
• Engine mounts
• Aircraft fuselage parts
• Landing gear components.

 

2- Automotive Industry

 

This industry has relied on CNC-based Aluminum machining. Aluminum is excellent at resisting rust and is durable. Therefore, manufacturers make different complex-shaped parts and components with this material. Its cost-effectiveness is an additional benefit.

 

Its low pricing helps manufacturers use parts by lowering the cost of their vehicles. Here is a list of automotive parts that are made with this process:

 

• Engine Parts
• Cylinder heads
• Transmission housings
• Suspension components 

 

The use of aluminum in the automobile industry is widespread. Why? Because it improves the fuel consumption of vehicles. The parts made by this material are lightweight. So, vehicles consisting of those parts are relatively less weight. As a result, they consume less fuel during their work.

 

3- Food/Pharmaceutical

 

Aluminum is non-toxic. It does not cause issues when used in food packages or cans. Some juicer machines come with blades made of aluminum material. So, you make juice with these machines. As aluminum is non-toxic, it does not add any toxicity while cutting the fluid and making juice. 

 

Similarly, the storage trays used in the pharmaceutical industry also contain aluminum. These trays remain in use for years without posing any threat. Here is the list of some other tools:

 

• Baking trays
• Mixing paddles
• Dosing equipment
• Storage containers
• Measuring devices

 

4- Marine Industry

 

CNC machining of aluminum is prevalent in both marine industries. Do I need to explain why? Let me give an overview. Aluminum is a corrosion-resistant material. Marine parts generally remain in contact with salty water. So they get eroded very quickly. 

 

However, aluminum’s corrosion resistance makes it very durable. It doesn’t get rusty fast, so this material is commonly used in making equipment. Here is a list of marine parts made with aluminum.

 

• Propeller shafts
• Boat hull fittings
• Engine components
• Deck cleats and hinges
• Marine brackets and mounts

 

5- Construction Industry

 

The construction industry heavily relies on strong but very inexpensive materials, right? Aluminum fulfills both of these criteria. It is strong and can bear stress with ease. However, I won’t say aluminum is the best material for this industry. Some other materials can have even more strength. 

 

However, its lower price generally attracts the manufacturers. Here are some parts (related to the construction industry) that are made by CNC machining of aluminum:

 

• Window frames
• Structural beams
• Curtain wall systems
• Roofing components
• Door handles and locks
• Handrails and guardrails

 

Frequently Asked Questions

 

Is CNC Machining of Aluminum Expensive?

No, the CNC machining of aluminum is not expensive. Its excellent machinability is something that makes it stand out. It can be cut easily, so machines don’t need extra effort. The cutting tools easily cut and shape it. So, CNC machining of aluminum is generally a cost-effective solution.

 

What are the challenges in Aluminum CNC machining?

Some aluminum alloys are very soft, making cutting them tedious. They can also break. Other challenges include their high thermal conductivity and tendency to build up edges. However, manufacturers have a solution for every challenge.

 

Can you CNC Aluminium?

Yes, the CNC machining of aluminum is possible. Many industries use aluminum through this CNC machining process. It offers precision with quick speed. The lightweight, excellent machinability and lack of brittle make aluminum a strong option for CNC machining.

 

What is CNC machining of aluminum?

It is a CNC-based manufacturing process. Computerized machines cut and shape aluminum with 100% precision at a breakneck pace. This method allows manufacturers to easily make complex-shaped parts of aluminum.

 

Conclusion

There is no doubt that aluminum offers unique properties. Excellent strength, corrosion resistance, and machinability make it stand out. However, CNC machining takes it to the next level. Manufacturers use this material to create very complex and intricate designs with ease. This guide offers the full scoop about this process and aluminum material.