The main points of custom CNC magnesium alloy parts mainly include the following aspects:
First, material selection and treatment
Material selection
Magnesium alloy type: Select the appropriate magnesium alloy type according to the application scenario and performance requirements of the part. Common magnesium alloys include AZ series (such as AZ91D, with good casting properties and mechanical properties), AM series (such as AM60, with good ductility and corrosion resistance), ZK series (such as ZK60, with high strength and hardness) and so on.
Purity and impurities: Select high-purity magnesium alloy materials to reduce impurity content to improve the machining performance and mechanical properties of parts.
Material pretreatment
Heat treatment: According to the performance requirements of the parts, the appropriate heat treatment of magnesium alloy, such as annealing, solution treatment, etc., to improve the structure and performance of the material.
Surface treatment: The surface treatment of magnesium alloy before processing, such as sandblasting, pickling, etc., to improve the surface quality and processing accuracy of the parts.
Second, design and modeling
Part design
Structural rationality: According to the use scenario and functional requirements of the parts, design a reasonable part structure to ensure the strength, stiffness and stability of the parts.
Processing convenience: Considering the characteristics of CNC processing, the design of parts structure that is easy to process, such as reducing deep holes, narrow grooves and other difficult to process features.
Three-dimensional modeling
Accurate modeling: Use CAD software for 3D modeling of parts to ensure dimensional accuracy and shape accuracy of parts.
Model verification: Simulation analysis of the built model to verify its structural rationality and processing feasibility.
Third, processing technology planning
Tool selection
Carbide cutting tool: Because the cutting performance of magnesium alloy is good, but it is easy to produce debris combustion, it is recommended to use carbide cutting tools for processing to improve processing efficiency and tool life.
Tool geometric parameters: According to the machining requirements of the parts, select the appropriate tool geometric parameters, such as front Angle, back Angle, edge inclination, etc.
Cutting parameter setting
Cutting speed: According to the material characteristics of magnesium alloy and processing requirements, set a reasonable cutting speed, generally between 100-200m/min.
Feed speed: According to the material characteristics of the tool and parts, set a reasonable feed speed, generally between 0.1-0.2mm/r.
Cutting depth: According to the machining allowance of the parts and the cutting ability of the tool, set a reasonable cutting depth, generally between 0.5-2.5mm.
Coolant selection
Water-soluble cutting fluid: Due to the low thermal conductivity of magnesium alloy, it is easy to produce high temperature, so it is recommended to use water-soluble cutting fluid for processing to reduce the cutting temperature and prevent debris combustion.
Mineral oil coolant: In some cases, mineral oil coolant can also be used for machining to improve processing efficiency and part surface quality.
Fourth, processing control
Machine tool selection
High-precision CNC machine tools: Select high-precision CNC machine tools for processing to ensure the machining accuracy and surface quality of parts.
Machine stability: Ensure the stability and rigidity of the machine to reduce vibration and deformation during processing.
Process monitoring
Real-time monitoring: Using sensors and monitoring systems, real-time monitoring of cutting force, temperature, vibration and other parameters during the machining process.
Timely adjustment: According to the monitoring results, timely adjustment of cutting parameters and tool wear to ensure the stability of the processing process and part quality.
Debris treatment
Debris collection: Use explosion-proof vacuum system and exhaust fan to collect debris and dust generated during processing in a timely manner.
Debris disposal: The collected debris is stored separately from the debris of other materials to prevent combustion or explosion accidents.
Fifth, post-processing and detection
Postprocessing
Deburring and cleaning: Use sandpaper, grinding and other tools to remove burrs and flash on the surface of the parts, and clean them.
Surface treatment: According to the requirements of the use of parts, surface treatment, such as spraying, anodizing, etc., to improve the corrosion resistance and beauty of the parts.
Quality inspection
Dimensional testing: Use coordinate measuring instrument and other testing equipment to comprehensively test the dimensional accuracy of parts.
Performance testing: The mechanical properties and corrosion resistance of the parts are tested to ensure that the parts meet the requirements of use.
Sixth, safety and environmental protection
Safety protection
Personal protection: Operators should wear protective clothing, goggles, gloves and other personal protective equipment to prevent debris splash and cutting fluid damage to the skin.
Working environment: Ensure that the working environment is well ventilated to reduce air pollution from cutting fluid and debris.
Environmental protection measures
Cutting fluid treatment: recovery and treatment of used cutting fluid to prevent pollution to the environment.
Debris disposal: The collected debris is stored and disposed of in a classified manner to prevent combustion or explosion accidents.
Seventh, cost control
Material utilization rate
Optimized design: Through optimized design, improve the utilization rate of materials and reduce material waste.
Reasonable arrangement: In the process of processing, reasonable arrangement of materials to reduce material cutting losses.
Processing efficiency
Optimization process: By optimizing the processing process, improve the processing efficiency and reduce the processing cost.
Equipment maintenance: Regular maintenance and maintenance of CNC machine tools to ensure the stability of equipment and processing efficiency.
