3C Electronics Profile Milling (Micro-Conical Structure) of Aluminum Alloy (Al6061)

📈 Quality - surface was smooth without defects | ⚙️ Tool Life - better chip evacuation prevents BUE on cutting tool
  • Difficulties in Machining
  • HIT Achievements
  • Industry Application
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What makes Al6061 Aluminum Alloy difficult to machine?



While aluminum alloy Al6061 is generally considered to have good machinability compared to many other metals, there are still some factors that can make it challenging to machine under certain conditions.

Aluminum alloy Al6061 can sometimes produce gummy chips during machining, especially when using high-speed machining techniques or insufficient lubrication. This can lead to poor surface finish and tool wear.

The tendency for aluminum to adhere to the cutting tool can result in the formation of built-up edge (BUE). This can cause cutting edges to become dull quickly, leading to poor surface finish and dimensional inaccuracies.

While aluminum is generally softer than many other metals, it can still cause tool wear due to its abrasive nature and tendency to adhere to cutting tools. Abrasive wear and tool buildup can reduce tool life and increase machining costs.


 
 

☑️ Al6061 (Aluminum Alloy) Machining Information

 
   Al6061 (Aluminum Alloy) Machining Information     
  Material   Al6061 Aluminum Alloy
  Feature   Φ2 ~ 0.2 x 8.5mm (micro-conical structure)
  Process   Profile Milling  
  Ultrasonic Tool Holder           HSKE40-R01-06
  Optimized Parameters   (Rough) S 24,000rpm; F 1,700mm/min; Ap 0.15mm; Ae 3mm
  (Mid) S 24,000rpm; F 1,100~1,400mm/min; Ap 0.1mm; Ae 0.21mm
  (Fine) S 24,000rpm; F 1,100~1,400mm/min; Ap 0.01mm; Ae 0.04mm
  Tool Selection   Φ4mm R0.1mm Torus milling cutter

 
HIT HSK-E40 ultrasonic machining module was used on profile milling of Al6061 aluminum alloy
(Figure 1. HIT HSK-E40 ultrasonic machining module was used on profile milling of Al6061 aluminum alloy)



 

HIT's Goal in Profile Milling (Micro-Conical Structure) of Aluminum Alloy (Al6061)


The goal is to do profile milling (micro-conical structure) of aluminum alloy with the torus milling cutter.  With HIT ultrasonic, it was expected to mitigate the tool marks on the surface and to reduce tool wear.



 

Ultrasonic-Assisted Profile Milling (Micro-Conical Structure) of Aluminum Alloy (Al6061): Machining Results

 

Aluminum Alloy (Al6061) Profile Milling (Micro-Conical Structure): Workpiece Quality

HIT ultrasonic-assisted profile milling of Al6061 aluminum alloy achieved better surface quality
(Figure 2. HIT ultrasonic-assisted profile milling of Al6061 aluminum alloy achieved better surface quality)

 
  • In conventional machining (without ultrasonic) of soft metal, usually there would be long and stringy chips due to material properties.  This would cause BUE (Built-Up Edge) on the tool and lead to increasing cutting forces.  BUE on the tool also resulted in obvious scratches left on the surface of workpiece.
  • With HIT ultrasonic, the high frequency micro-vibration helped with better chip evacuation.  The tool could cut off the material more easily, which helped prevent the increasing cutting forces.  Surface of workpiece was smooth without defects, and the consistent marks showed the tool received uniform forces during machining.




 

Aluminum Alloy (Al6061) Profile Milling (Micro-Conical Structure): Tool Life

HIT ultrasonic-assisted profile milling of Al6061 aluminum alloy brought better chip evacuation, preventing the occurrence of BUE
(Figure 3. HIT ultrasonic-assisted profile milling of Al6061 aluminum alloy brought better chip evacuation, preventing the occurrence of BUE)

 
  • In conventional machining, BUE on the tool caused high cutting forces.  This not only damaged the surface of workpiece, but also caused serious tool wear.
  • With HIT ultrasonic, better chip evacuation helped prevent BUE on the tool.  There showed not much difference between the new tool and the used tool (with HIT ultrasonic).




 

HIT Ultrasonic Technology Achievements in Profile Milling of Aluminum Alloy (Al6061)


📈 Quality -  surface was smooth without defects
⚙️ Tool Life - better chip evacuation prevents BUE on cutting tool

 

Aluminum Alloy (Al6061) Profile Milling (Micro-Conical Structure) in Industry Application



Profile Milling of Aluminum Alloy (Al6061) is often applied in the Electronics industry, especially for electronic components, such as enclosures, heat sinks, brackets, and chassis, etc.


Aluminum alloy (Al6061) offers good strength properties, making it suitable for structural applications. It has a tensile strength ranging from 276 to 310 MPa (40,000 to 45,000 psi) depending on the temper.  It has good machinability, allowing for ease of machining processes such as milling, drilling, turning, and tapping. This property makes it popular for manufacturing various components and parts.

The material also exhibits good resistance to corrosion, particularly in environments with mild alkaline and acidic conditions. However, it is susceptible to corrosion in highly corrosive environments such as those containing chlorides. 

Aluminum alloy Al6061 has a relatively high thermal conductivity, which makes it useful for applications requiring efficient heat transfer, such as heat sinks and thermal management components in electronic devices.


HIT's Ultrasonic Machining Module offers a comprehensive solution in machining these difficult-to-cut materials.  With the assistance of HIT's Ultrasonic Machining Technology, clients stopped worrying about poor surface quality and tool life.  Not only the surface quality and tool life can be improved, but the machining efficiency can also be greatly enhanced.  HIT assures its clients of matching up with their requirements and achieving even better outcomes!



💡 Learn more about other HIT Ultrasonic Machining of metal alloys, alloy steel, tool steel, carbide mould cases

💡 Introduction on HIT Ultrasonic Machining on metal alloys, carbide mould, etc.