Compared with ferrous metal, aluminum alloy has its own special machinability, so it also has specific requirements for the performance of cutting fluid. In the process of aluminum alloy machining, problems such as sticking knife, tapping rotten teeth and moldy non machined surface are easy to occur, which requires comprehensive consideration from two aspects: the design and use of cutting fluid products. In the design of cutting fluid products, factors such as lubrication, corrosion inhibition and residue required for aluminum alloy processing shall be considered. In the use of cutting fluid products, the optimal scheme shall be formulated according to the specific conditions such as aluminum alloy workpiece material, aluminum alloy processing mode, processing time, stacking mode, circulation time and cleaning requirements. Based on these factors, some common problems in aluminum alloy processing are briefly discussed below:
1. Rotten teeth, sticking knife and unqualified finish of machined surface during tapping
Aluminum alloy has soft properties and low melting point, so it is easy to have problems such as rotten teeth or sticking knife in poor processing environment. In addition to changing processing parameters, such as avoiding medium speed processing that is easy to stick knife, cutting fluid with good lubrication and cooling performance should be used. Huiwen has long been committed to the processing of metal and plastic parts with high precision, high difficulty and easy deformation, small and medium-sized batch production and manufacturing of light alloy and composite materials (such as aluminum alloy, carbon fiber, etc.), and robot parts procurement and customization services.
2. Moldy non machined surface
Most of the problems in aluminum alloy machining are caused by cutting fluid. The lack of cutting fluid product design means that it is difficult to avoid problems in the machining process. The non machining of die casting aluminum alloy has a sensitive response to the corrosion inhibition ability of cutting fluid, and mildew is one of its manifestations. Aluminum alloy mildewing is usually caused by insufficient aluminum corrosion inhibition ability of cutting fluid and insufficient microbial control ability of cutting fluid. The mildewing phenomena caused by the two reasons are different, but in most cases, the mildewing is caused by insufficient aluminum corrosion inhibition ability of cutting fluid. When mildew occurs, we should start with the improvement of corrosion inhibition ability of cutting fluid and the improvement of storage mode after machining.
3. The residue on the machined surface affects the later cleaning
Aluminum alloy generally needs cleaning process after machining. If the cleaning ability of cutting fluid for aluminum alloy parts is not good, residues will be generated on the aluminum alloy machining surface, affecting the appearance or later code spraying treatment. It is usually related to the design of emulsification system and cleaning process of cutting fluid products.
4. A large amount of foam is produced during the processing of aluminum alloy parts.
Cutting fluid foam is usually avoided during machining. Inadequate cooling caused by foam and severe tool wear will result in poor machining results and low machining efficiency. Especially with the renewal of machine tools, the five axis machining center has higher requirements for cutting fluid foam, and the cutting fluid which is short of anti foaming and defoaming ability will cause abnormal elevation of liquid level, and trigger the liquid level alarm to make the machine tool stop working normally. The improvement of the performance of cutting fluid foam can be solved not only by adding defoamer but also from the system design of cutting fluid products.
5. Short service life of cutting fluid
In the process of machining aluminum alloy workpieces such as piston, gearbox cylinder block and so on, there is a common problem of short service life of cutting fluid. The service life of cutting fluid is not only related to the frequency of groove changing and the cost of investment, but also affects the processing quality, on-site working environment and so on. Huiwen is good at CNC processing: CNC turning, milling, drilling, grinding, sheet metal processing and other processes (CNC machining of precision parts). The service life of cutting fluid is mainly reflected in the sticking and corruption of groove fluid after being used for a period of time.