Our 5-axis CNC aluminum parts are designed to meet the rigorous demands of the automotive sector, providing reliable performance in critical applications while maintaining the highest quality standards throughout the manufacturing process.
Design Optimization & Programming
(1) DFM (Design for Manufacturability) Analysis: The supplier often performs DFM analysis, offering suggestions to the client on design details to optimize part structure, improve machinability, and reduce costs without compromising performance. This might involve adjusting wall thickness, adding chamfers, or avoiding deep, narrow grooves.
(2) Material Selection & Preparation: Based on design requirements, the appropriate aluminum alloy grade (e.g., 6061, 7075) is selected, and raw material of the required dimensions is prepared.
(3) CAM Programming: This is the core of 5-axis CNC machining. We use professional CAM (Computer-Aided Manufacturing) software to generate detailed tool paths and machining code (G-code) from the 3D model. 5-axis machining specifically requires precise programming to leverage its multi-axis capabilities, allowing for the machining of complex surfaces and features, and optimizing cutting angles, feed rates, and spindle speeds to ensure machining efficiency and surface finish.
(4) Simulation & Verification: Before actual machining, CAM software is typically used for machining simulation to simulate tool paths, check for collisions or overcuts, and ensure a safe and error-free machining process.
5-Axis CNC Machining
(1) Equipment Setup & Workholding Fixtures: The aluminum raw material is secured in fixtures on the 5-axis CNC machining center. For complex parts, custom workholding fixtures may need to be designed to ensure stability and accuracy during machining.
(2) Part Machining: The operator uploads the CAM-generated G-code to the 5-axis CNC machining center and initiates the machining process. 5-axis machines can move simultaneously along three linear axes (X, Y, Z) and two rotary axes (A, B, or C), allowing for the completion of multiple faces and angles of complex parts in a single setup, reducing refixturing and improving machining accuracy and efficiency.
(3) Process Monitoring: During machining, the operator continuously monitors machine operation, tool wear, coolant supply, and machining quality, making timely parameter adjustments or tool changes as needed.
Post-Processing & Surface Treatment
(1) Deburring & Cleaning: After machining, all burrs and sharp edges are removed, and the part is cleaned to remove cutting fluid and debris.
(2) Surface Treatment (Optional): Based on client requirements, various surface treatments are applied to the aluminum parts to enhance their corrosion resistance, wear resistance, aesthetics, or electrical conductivity. Common surface treatments include:
(3) Anodizing: Forms a hard, corrosion-resistant oxide layer, which can be colored.
(4) Sandblasting/Bead Blasting: Achieves a uniform matte finish.
(5) Polishing: Creates a high-gloss surface.
(6) Chromate Conversion Coating: Provides corrosion protection and good electrical conductivity.
(7) Electrophoresis, Painting, etc.
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