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How to reduce processing deformation of embossed aluminum plate
Nov 20, 2020

1. Thin-walled workpieces are deformed due to clamping during processing, even finishing is unavoidable. In order to reduce the deformation of the workpiece to a lower limit, the compression piece can be loosened before the finishing process reaches the size, so that the workpiece can be restored to its original shape freely, and then slightly compressed, subject to the rigid clamping of the workpiece (completely By hand), so you can get the ideal processing effect. In short, the point of action of the clamping force is better on the supporting surface, and the clamping force should act in the direction of good rigidity of the workpiece. Under the premise of ensuring that the workpiece is not loosened, the smaller the clamping force, the better.

2. When machining parts with a cavity, try not to let the milling cutter plunge directly into the part like a drill bit, resulting in insufficient chip holding space of the milling cutter, unsmooth chip removal, and overheating, expansion and collapse of the part. Unfavorable phenomena such as knife and broken knife. First, drill the hole with a drill of the same size as the milling cutter or one size larger, and then mill with the milling cutter. Alternatively, the CAM software can be used to produce the spiral cutting program.

3. The order of the knife should also be paid attention to. Rough machining emphasizes the improvement of machining efficiency and the pursuit of removal rate per unit time. Generally, up-cut milling can be used. That is, the excess material on the surface of the blank is removed at a relatively fast speed and time, and the geometric contour required for finishing is basically formed. The emphasis of finishing is high precision and high quality, and down milling should be used. Because the cutting thickness of the cutter teeth gradually decreases from larger to zero during down milling, the degree of work hardening is greatly reduced, while reducing the degree of deformation of the parts.

4. If there are multiple cavities on the sheet metal parts, it is not advisable to use a cavity-by-cavity sequential processing method during processing, as this will easily cause uneven stress and deformation of the parts. Multi-layer processing is adopted, and each layer is processed to all cavities at the same time as much as possible, and then the next layer is processed to make the parts evenly stressed and reduce deformation.

5. Reduce cutting force and cutting heat by changing cutting amount. Among the three elements of cutting amount, the amount of back-cutting has a great influence on cutting force. If the machining allowance is too large, the cutting force of one pass is too large, which will not only deform the parts, but also affect the rigidity of the machine tool spindle and reduce the durability of the tool. If you reduce the amount of knives backed, the production efficiency will be greatly reduced. However, high-speed milling is used in CNC machining, which can overcome this problem. While reducing the amount of back-grabbing, as long as the feed is increased correspondingly and the speed of the machine tool is increased, the cutting force can be reduced while ensuring the processing efficiency.

6. For parts with large machining allowance, in order to have better heat dissipation conditions during the machining process and avoid heat concentration, symmetrical machining should be used during machining. If there is a 90mm thick sheet that needs to be processed to 60mm, if one side is milled and the other side is milled immediately, the flatness will reach 5mm; if the repeated feed symmetrical processing is used, each side is processed twice To the size, the flatness can be ensured to reach 0.3mm.