CNC Zinc Alloy Processing
Zinc alloy machining is the process of performing various machining operations on zinc alloy materials to obtain parts or products of the desired shape, size and surface quality. Here are some introductions to zinc alloy machining:
1. Influence of the characteristics of zinc alloys on machining:
- Advantages:
- Good casting performance: Zinc alloy has a low melting point, which makes it easy to achieve melt casting, with high fluidity and mould filling capacity, and can adapt to complex casting shapes and sizes, which provides a better blank base for machining and reduces the difficulty of machining. For example, some structurally complex zinc alloy parts, through die-casting and other casting methods after moulding, and then machining can obtain higher precision and surface quality.
- Better machining performance: zinc alloy can be cut, drilled, tapped and other processing methods for processing, and processing tool wear is relatively small, to ensure high processing efficiency and processing quality.
- Good surface treatment performance: zinc alloy die casting surface treatment is relatively easy, can be plated, sprayed, baked paint and other surface treatment processes, after machining zinc alloy parts can better adapt to a variety of surface treatment requirements, improve the appearance of the product quality and corrosion resistance.
- Disadvantages:
- Low creep strength: zinc alloy is prone to creep deformation under long-term stress, which puts forward higher requirements for precision control of machining. In the machining process, it is necessary to reasonably select the machining process and machining parameters to reduce the impact of machining stress on the size and shape of the part.
- Poor dimensional stability: zinc alloy is prone to dimensional changes caused by natural aging, which needs to be considered in the machining process. For some parts with high requirements for dimensional accuracy, appropriate aging treatment is needed after machining to ensure the dimensional stability of the parts.
2. The main machining process:
- Cutting processing:
- Turning: It can be used to process zinc alloy rotary parts, such as shafts, disc parts and so on. Turning can obtain high dimensional accuracy and surface quality, and can process a variety of shapes of the outer circle, inner hole, conical surface, threads, etc.. When turning zinc alloy, it is necessary to choose suitable tool materials and cutting parameters to ensure processing efficiency and processing quality.
- Milling: It is suitable for machining flat surfaces, grooves, steps, gears and other parts of zinc alloy. Milling can be done by vertical milling, horizontal milling, etc. Different milling cutters and machining processes are selected according to the shape of the parts and machining requirements. Milling can obtain high machining accuracy and surface quality, and the machining efficiency is high.
- Drilling: It is used to process holes in zinc alloy parts, including through holes, blind holes, step holes and so on. Drilling requires the selection of appropriate drill bits and drilling parameters to ensure the dimensional accuracy and surface quality of the holes. When drilling deep holes, chip removal and cooling problems also need to be considered to prevent overheating and seizing of the drill bit.
- Grinding: For some zinc alloy parts with high requirements for surface quality and dimensional accuracy, grinding is required. Grinding can remove burrs, scratches and oxidised layer on the surface of the parts and improve the surface quality and dimensional accuracy of the parts. Grinding can be done by plane grinding, external grinding, internal grinding, etc. Different grinding machines and grinding processes are selected according to the shape and processing requirements of the parts.
- EDM: In processing some zinc alloy parts with complex shape and high hardness, EDM can be used. EDM uses the discharge phenomenon between the electrode and the workpiece to remove the material, and can process various shapes of parts with high machining accuracy. However, the efficiency of EDM is low and the cost is high, and it is generally only used to process some parts with special requirements.
3. Precautions in the machining process:
- Tool selection: Since the hardness of zinc alloy is relatively low, when selecting a tool, a sharp tool should be chosen to reduce the cutting force and cutting heat, and to prevent the parts from deformation and burns. At the same time, the material of the tool should have better wear resistance and heat resistance to ensure the service life of the tool.
- Cutting parameter selection: When selecting cutting parameters, cutting speed, feed and depth of cut should be reasonably selected according to the material properties of zinc alloy and the processing requirements of the parts. Generally speaking, the cutting speed should not be too high, the feed should not be too large, and the cutting depth should be reasonably selected according to the shape and size of the parts to ensure the machining efficiency and machining quality.
- Cooling and lubrication: In the machining process, appropriate cooling and lubrication measures should be used to reduce the cutting temperature, reduce tool wear, and improve the machining surface quality. Commonly used cooling and lubrication methods include cutting fluid cooling, air cooling and grease lubrication.
- Machining accuracy control: Because of the poor dimensional stability of zinc alloy, the control of machining accuracy should be strengthened in the machining process. Multiple machining and aging treatment can be used to ensure the dimensional accuracy and shape accuracy of the parts.
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