Is Horizontal CNC Milling a Good Fit for Aluminum Parts

Many structural components we see around are made up of aluminum. This metal is the go-to material for many industrial applications because of its unique properties. From engine blocks to surgical instruments, there are various ways you can use aluminum alloy. Aluminum is lightweight and comes with remarkable strength. Additionally, it has a high thermal and electrical conductivity. 

However, can horizontal CNC milling meet the machining needs of aluminum? Yes, you can cut aluminum workpieces using horizontal CNC machines seamlessly. This article will explain why horizontal CNC milling is a good fit for aluminum, how to machine aluminum parts with horizontal machines, and the applications of horizontal CNC milling aluminum. 

What is Horizontal CNC Milling

Horizontal CNC milling is a milling operation carried out using a horizontal machine. This machine has its spindle oriented parallel to the ground. You place the workpiece on the table while the tool moves horizontally along different axes to cut through. This feature allows you to handle large workpieces and make deep cuts. 

Furthermore, horizontal CNC milling is preferred over the vertical type in many cases. Horizontal CNC milling is efficient in large-scale production. It is fast and removes more material in one pass. Additionally, it improves chip evacuation, which makes the milling process more straightforward. 

Is Horizontal CNC Milling a Good Fit for Aluminum Parts

Yes, horizontal CNC milling is an excellent technique for aluminum workpieces. It machines aluminum well to produce accurate and high-quality parts. When working on aluminum workpieces, it is essential to modify CNC milling parameters based on the particular aluminum alloy. This will ensure a smooth operation and reduce the incidence of defects. 

Furthermore, many factors are responsible for the compatibility between horizontal CNC milling and aluminum metals. Some of these factors include

• Aluminum Properties

The innate properties of aluminum make it possible to cut with a horizontal milling machine. Aluminum is lightweight, soft and easy to handle. Additionally, it has a high thermal conductivity, which prevents heat build-up during horizontal milling operations. 

• Production Efficiency 

Using horizontal CNC milling with aluminum alloys improves production efficiency. You can be sure of high material removal rates because the machines are more stable. With this technique, multi-sided machining is possible. You can work on different sides in a single setup. 

• Complexity

Horizontal CNC milling is better suited for large and complex-shaped aluminum parts. The reasons behind this are not far-fetched. The beds of horizontal machines are large and can accommodate heavy workpieces. The machine works well with CAD models with detailed designs and features. 

• Chip Evacuation

Aluminum machining will inevitably produce chips. Using horizontal CNC machines prevents chip build-up and aids chip removal. This is because gravity pulls the chips and keeps the work area clean. 

How to Machine Aluminum Parts with Horizontal CNC Milling

The process of machining aluminum workpieces using a horizontal milling machine requires a series of steps. Let’s discuss the process in detail. 

#1- Designing Phase

The first step is to create a design of what you want the final part to look like. You do this using CAD software such as SOLIDWORKS and AutoCAD. After that, you will convert the model to a language the machine understands. These programming languages, including G codes and M codes, control the movement of the cutting tools. 

#2- Workpiece Preparation 

The next step is to select a suitable aluminum alloy and adequately prepare the workpiece. Preparation involves cleaning the workpiece to remove all forms of contaminants. To go about this, use appropriate cleaning agents, which can be neutral or alkaline. Workpiece preparation is vital as contaminants cause unwanted reactions and poor surface finish. 

#3- Machine Setup And Tool Selection

You then set up the horizontal CNC milling machine. This entails cleaning it and mounting the aluminum workpiece on the table. Carefully clamp the part using workholding jigs and fixtures. For the cutting tool, choose one that is optimised for aluminum alloys. If possible, the tool should have large flutes and be made from high-speed steel or carbide. This will ensure sufficient chip evacuation and prevent the workpiece from sticking. 

#4- Machining Process

Once everything is set, optimize the cutting parameters such as spindle speed, feed rate and depth of cut. The workpiece properties and thickness level will affect the setting you use. After that, execute the operation and mill the part. The machine runs uninterrupted till the program ends. 

#5- Finishing and Inspection 

The final phase of horizontal CNC milling aluminum involves inspecting the product for defects and flaws. Check if the final surface finish is sufficient for functionality. You should also assess for dimensional accuracy using hand metrology tools or coordinate measuring machines. 

Applications of Horizontal CNC Milling Aluminum

There are a thousand and one ways you can use horizontally milled aluminum parts. CNC-machined parts are versatile and suitable in many manufacturing industries. Some of the applications of horizontal CNC milling aluminum are 

• Aerospace Industry 

Using CNC-milled aluminum components in the aerospace industry is nothing new. This technique can produce long and complex shaped parts with intricate features used in this industry. Examples of horizontal CNC milling aerospace parts include wing spars, fuselage frames, and landing gear components. 

• Automotive Industry 

Auto part manufacturers use horizontal CNC milling aluminum extensively. Aluminum has an excellent strength-to-weight ratio, which makes it the ideal material for car components. Utilising this milling method when fabricating engine components, transmission housing, and chassis reinforcements increases fuel efficiency. 

• Electronic Industry 

Another sector you can employ horizontal CNC milling aluminum is electrical and electronics. Aluminum is a good conductor of heat and prevents overheating that can lead to damage. With horizontal CNC milling, you can be sure of accurate and repeatable electronic components such as device housings, heat sinks, and connectors. 

• Medical Industry 

Horizontal CNC milling aluminum meets many of the requirements in the medical industry. The parts are safe and easy to clean. Additionally, CNC-milled aluminum components are corrosion-resistant and won’t degrade when in contact with bodily fluids. This makes horizontal CNC milling aluminum the method of choice when fabricating surgical devices, components of imaging equipment, and orthopaedic implants. 

Conclusion

Horizontal CNC milling is an excellent way to process aluminum workpieces. This technique removes a large quantity of material per pass. Hence, you can be sure of shortened lead time and enhanced overall productivity. Is horizontal CNC milling a good fit for aluminum parts? How can you use a milling machine to cut aluminum workpieces accurately? We hope this article has answered all your questions. For further questions and clarifications? Reach out to a reputable CNC milling service provider today.