Machining Of Aluminum Profiles

Mechanical processing for aluminium profiles includes a variety of processes to machine aluminium profiles according to specific requirements. Here are the most common methods:

1. Sawing: Mitre Cuts & Precision Cuts

Cutting aluminium profiles requires special tools and techniques to achieve precise results and prevent damage to the material. Here are some important points to bear in mind:

1.1 Suitable tools

• Circular saw: Carbide saw blades designed for aluminium. These blades usually have a special tooth geometry that ensures clean cuts.
• Band saws: Suitable for larger workpieces or more complex cuts.
• Water jet or laser cutters: For very precise or complex cuts, often in industrial applications.

1.2 Cooling and lubrication

Aluminium can easily overheat during cutting, which can affect the quality of the cut. Cooling (e.g. with cutting oil or emulsions) is important to prevent overheating and extend the service life of the tools.

1.3 Material tension

Aluminium profiles should be well clamped before cutting to minimise vibrations and ensure precise cuts.

1.4 Cutting tolerances

Depending on the application, certain tolerances must be adhered to. Precise cutting is particularly important in manufacturing or construction.

1.5 Protective measures

Aluminium chips can be sharp. Wearing safety goggles, gloves and hearing protection is recommended.

1.6 Reworking

The cut edges can be deburred to remove sharp edges and ensure a clean finish.

2.Drilling: Creating holes with precise diameters in preparation for screws, bolts or threaded holes.

Aluminium profiles can be drilled in different ways, depending on the application and specific requirements. Here are the most common drilling types for aluminium profiles:

2.1 Through hole

Holes that pass completely through the profile and are used for mounting or connecting aluminium profiles with screws or bolts.

2.2 Blind hole

Holes that do not run completely through the profile and have a certain depth,e.g. normal holes or threaded holes. Threaded holes allow direct screwing into the profile without additional nuts.

2.3 Countersunk hole

A drilled hole that is widened at the edge to allow screw heads to be inserted flush. Often used for visually appealing or flush screw connections.

2.4 Slotted hole

An elongated, oval hole created by milling or special drilling. Used for adjustment options or other flexible connections and water slots in the construction industry.

2.5 Cross hole

A hole that is drilled at right angles to a main axis of the profile. Used to connect cross pieces or to mount accessories.

3.Milling: The milling of aluminium profiles is an important processing step, especially in metalworking, in order to make precise shapes, recesses or adjustments.Aluminium lends itself well to milling as it is light and relatively soft, making it easy to machine.

3.1 Typical applications:

• Production of technical components.
• Machining of profiles for mechanical engineering, vehicle construction or electronics.
• Production of housings, frames or connecting elements.

3.2 Important aspects of milling aluminium profiles:

• Milling tools:Carbide or diamond tools are ideal for aluminium.High cutting speeds and sharp cutting edges are necessary to avoid material adhesion.
• Lubricants: Use of cooling lubricants to prevent overheating and material build-up.
• Machine parameters:High rotational speeds and feed rates.Low cutting forces by adjusting the milling depth.
• Surface quality: To ensure a clean surface without burrs, the machine should be set precisely.

4.Turning: Aluminium profiles are machined to achieve precise shapes, dimensions and surface qualities.

The workpiece is clamped on a lathe and machined with a rotating cutting tool.

4.1 Advantages of turning aluminium profiles:

• High precision: Ideal for complex geometries and tight tolerances.
• Smooth surfaces: Fine surfaces can be achieved with the right machining.
• Fast machining: Aluminium is a relatively soft material, which means it can be machined efficiently.
• Flexibility: Suitable for prototypes, small batches and series production.

5.Thread Cutting

5.1 The tapping process:

• Preparation: the aluminium profile is fixed in place to prevent movement during cutting. If necessary, a pilot hole is drilled in order to be able to cut the thread precisely.
• Tools:Internal thread: Is cut with a tap.External thread: Produced with a die or using a lathe.
• Cutting process:The tool is inserted into the material to create the desired thread form (e.g.metric or imperial thread).Lubricant is often used to reduce friction and heat.

5.2 Special features of aluminium:

Aluminium is a soft and light metal. This makes it easier to cut, but requires special care to avoid burrs and material deformation.Special taps or dies for aluminium should be used to ensure clean cuts.Proper lubrication prevents aluminium from sticking to the tool.

Areas of application:Fastening structures in mechanical engineering, the automotive industry or architecture.Assembly of aluminium frames in solar systems or window construction.

6.Bending: Aluminium profiles are bent into specific shapes to produce frames or curved constructions.

7.Punching: Material is pressed by a punch into a mould with a die figure.mould figure.

8.Grinding: Surface treatment to remove burrs or to refine for optical and technical requirements.

9.CNC Machining: High-precision machining by computer controlled machines with advantages such as precision, repeatability and complexity in geometry.

10.Welding: Joining of aluminium parts.

10.1 Types:

• MIG and TIG welding
• Spot and friction welding

Conclusion:

The choice of machining process depends on the requirements, such as precision, quantity and design. Mechanical processing extends the range of applications for aluminium profiles in almost all industrial sectors.