The reasons why aluminum parts are easily deformed during processing are:
The cooling speed is too slow: When the aluminum plate is processed without sufficient cooling, the internal heat cannot be dissipated in time, causing the aluminum plate to deform.
Uneven stress during processing: Uneven stress during processing will cause local deformation of the aluminum plate, and local deformation will increase the stress on other parts, causing greater deformation.
Uneven internal structure of the material: Uneven internal structure of the material will cause uneven internal stress distribution during the processing of the aluminum plate, resulting in deformation.
Residual stress: During the forming process of metal materials, the arrangement of metal crystals is not the neat arrangement in the ideal state. The size and shape of the crystals are different. This results in an original residual stress, which is slowly released over time. in certain deformations.
In order to reduce deformation during the processing of aluminum parts, a series of measures can be taken, such as pre-stretching, strengthening cooling measures, strengthening material quality control, etc.
Methods to reduce deformation of aluminum parts during processing include:
Symmetrical processing method: For aluminum alloy parts with large machining allowances, in order to create better heat dissipation conditions and reduce thermal deformation, excessive heat concentration should be avoided. The method that can be adopted is symmetrical processing.
Multiple layered processing method: When there are multiple cavities that need to be processed on aluminum alloy plate parts, if the one cavity processing method, one cavity in sequence is used, the wall of the cavity will easily deform due to uneven stress. Therefore, a layered and multiple processing method can be used. Each layer is processed in all cavities at the same time, then the next layer is processed to make the parts uniformly stressed and reduce deformation.
Proper selection of cutting dosage: Reduce the cutting force and cutting heat by changing the cutting dosage. Reducing the amount of undercut will help ensure that the part does not warp, but at the same time it will reduce processing efficiency. It is therefore necessary to choose the appropriate cutting amount.
Pay attention to the tool pass sequence: roughing and finishing should use different tool pass sequences.
Secondary compression of thin-walled parts: When processing thin-walled aluminum alloy parts, the pressing force during clamping is also an important cause of deformation, which is inevitable even if the processing precision is improved. In order to reduce the deformation of the workpiece due to clamping, you can loosen the pressed parts before reaching the final size when finishing, release the pressing force, allow the parts to return to their original shape freely, and then press lightly again.
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