Preventing deformation of parts in aluminum alloy processing is the key to ensuring processing quality and precision. The following are seven practical anti-deformation methods:
1. Symmetrical processing method: For aluminum alloy parts with large processing allowances, symmetrical processing method can be adopted to avoid excessive heat concentration and thermal deformation. By repeatedly feeding on both sides, each surface is processed at least twice until the final size is reached, which is conducive to heat dissipation and reduces deformation.
2. Layered multiple processing method: When there are multiple cavities on aluminum alloy plate parts that need to be processed, layered multiple processing method should be adopted. All cavities are processed at the same time, but divided into several layers, and processed layer by layer to the required size, so that the parts are evenly stressed and the probability of deformation is reduced.
3. Appropriate selection of cutting amount: Choosing the appropriate cutting amount can effectively reduce the cutting force and cutting heat during the cutting process. Excessive cutting amount will lead to excessive cutting force, which is easy to cause part deformation. Therefore, among the various elements of cutting amount, the back cutting amount, feed amount and cutting speed should be reasonably controlled.
4. Improve the cutting ability of the tool: The material and geometric parameters of the tool have an important influence on the cutting force and cutting heat.
Selecting appropriate tool geometry parameters, such as appropriately increasing the rake angle, selecting the back angle according to the cutting thickness, selecting the largest helix angle possible, and appropriately reducing the main deflection angle, can improve heat dissipation conditions, reduce cutting forces and cutting temperatures. Improve tool structure, reduce the number of milling cutter teeth, and increase chip space to avoid deformation of thin-walled aluminum alloy parts caused by chip blockage.
5. Pay attention to the order of cutting: Roughing and finishing should adopt different cutting orders. Roughing emphasizes processing efficiency and pursues material removal rate per unit time. Generally, reverse milling can be used. Finishing emphasizes processing quality and surface accuracy. Down milling should be used to reduce the degree of deformation of parts.
6. Secondary clamping of thin-walled parts: When processing aluminum alloy thin-walled parts, the clamping force during clamping is also an important cause of deformation. In order to reduce the deformation of the workpiece caused by clamping, the clamped parts can be loosened before the final size is reached in the finishing process, the clamping force can be released, the parts can be freely restored to their original state, and then slightly clamped again.
7. Drilling before milling: When machining parts with cavities, if the milling cutter is directly inserted into the part, the chip removal will be poor due to the insufficient chip space of the milling cutter, resulting in the accumulation of a large amount of cutting heat and expansion deformation of the part.
Therefore, the tool hole should be drilled with a drill bit that is not smaller than the milling cutter, and then the milling cutter should be inserted into the tool hole to start milling, which can effectively solve the problems of poor chip removal and deformation.
In summary, by adopting practical methods such as symmetrical processing method, layered multiple processing method, appropriate selection of cutting amount, improvement of tool cutting ability, attention to tool path sequence, secondary clamping of thin-walled parts, and drilling before milling, the deformation of parts in the aluminum alloy processing process can be effectively prevented.(来源：UG学习堂小胥收徒)
