Aluminium is a remarkably common material that is used in various applications in Australia. The material is widely used due to its malleability, lightweight, abundance, resistance to corrosion, and flexibility in processes such as machining, rolling, and forming. Here are some facts that new metal fabricators should bear in mind when machining aluminium. 

Lubrication -- Lubrication is regarded as an integral step in cutting aluminium. Lubrication helps to prevent adhesion between the cutting tool and aluminium chips. Also, lubrication serves the purpose of eliminating chips from workpieces and tools. Besides, metal fabricators use lubricants to minimise the temperature created during the cutting process. For instance, when you drill through aluminium without lubrication, there is a high likelihood of chips collecting around the hole or squeezing between the workpiece and the drill. It leads to surface lacerations. In such an instance, make sure to remove the chips using compressed air. Also, coolant liquid can be flushed through the drill to force out the chips, especially in deep holes. Lubrication also eliminates thermal shock issues in cutting tools. 

Velocity -- Metal fabricators must consider the velocity of cutting, which has a direct bearing on the temperature at the tool point. High speed, especially on ductile materials, is likely to cause the formation of longer and less distorted chips that will necessitate the use of an artificial chip breaker. If the speed is very slow, then the temperature at the region between the working piece and the tool will be below the recrystallisation temperature of aluminium. The low velocity leads to the hardening of chips and the formation of the built-up edge. Fabricators should stick to the recommended cutting speeds for drilling, milling, and turning aluminium. 

Tool Coating -- In aluminium machining application, the goal is to reduce edge built-up. One way of achieving this is by tool coating aluminium using zirconium nitrides, diamond and chrome nitrides, among other coatings. Coatings can improve the life of the cutting tool while producing a chemically inert surface. Diamond coatings, although expensive, are the best in this category. Fabricators should research about the best coats that work well with aluminium machining processes of their choice.  

Tool Geometry -- High-speed aluminium machining tools should be designed to increase space for chip evacuation. Aluminium, being a soft material, can increase the feed rate, thereby causing high chip production. Superior quality cuts can be attained by using a cutting tool with improved strength.  

Reach out to a professional to learn more about aluminium cutting.