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Understanding the Composition of Aluminum Alloys Can Boost Milling Productivity

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Understanding the Composition of Aluminum Alloys Can Boost Milling Productivity ➤ BY EDMUND ISAKOV, P h . D . Composition Matters Understanding the composition of aluminum alloys can boost milling productivity. Part 1 of 2 t’s a metal that people come into contact with every day—from cans to cars to you name it. The metal is aluminum, and it’s classified into two major groups: wrought and cast. IThe first part of this two-part ar- ticle covers the designation system for wrought aluminum and aluminum alloys and their temper (a process that improves physical and mechanical properties), the relationship between hardness of aluminum alloys and their strength, milling data and a method of calculating the machining power re- quired to maximize productivity from a given machine tool. Ingersoll Cutting Tools designated 8xxx. Alloy Designation In the 1xxx group, the series 10xx designates unalloyed The designation system for wrought aluminum and aluminum grades that have natural impurity limits. Des- aluminum alloys was developed by the American National ignations having a second digit other than zero (integers 1 Standards Institute (ANSI) and adopted by The Aluminum through 9) indicate special control of one or more individual Association Inc. in the United States. impurities, such as 11xx, 12xx, 13xx and 14xx. The last two A four-digit numerical designation system is used to of the four digits in the designation indicate the minimum identify wrought aluminum and aluminum alloys, which aluminum percentage to the nearest 0.01 percent. For exam- are divided into eight groups. The first digit indicates the ple, the 1098 grade contains 99.98 percent aluminum. Cur- following groups. rently, there are nearly 40 grades containing 99.00 to 99.99 Equal to or greater than 99.0 percent aluminum is desig- percent aluminum, from 1100 (99.00 percent) to 1199 (99.99 nated 1xxx. Aluminum alloys are grouped by major alloying percent). These are used primarily in the electrical and element or elements. An aluminum alloy with copper as chemical fields for products such as conductors, capacitors, the major alloying element is designated 2xxx, manganese heat exchangers, packaging foil and chemical equipment. is 3xxx, silicon is 4xxx, magnesium is 5xxx, magnesium Aluminum is characterized by excellent corrosion re- and silicon is 6xxx and zinc is 7xxx. Other elements are sistance and high electrical and thermal conductivities. Does roughing operation qualify as high-speed machining? he following case study is based on information provided Machining power and torque requirements. Tby Perry Keifer, machine shop manager for Rovema Pack- Tempers of 6061 aluminum alloy aging USA, Lawrenceville, Ga. 0 T4 T6 Workpiece material: Blocks of 6061-T6 aluminum End product: Disc brake calipers for racecars Brinell hardness at 500 kg load 30 65 95 Cutting tool: Integral-shank endmill, high-positive axial Ultimate tensile strength, psi 18,000 35,000 45,000 geometry, indexable carbide inserts with grade DC 20 dia- Tangential cutting force, lbs. 91 177 228 mond coating Required machining power, hp 15.2 29.6 38.0 Tool diameter (D): 2.0" Number of inserts (Z): 5 Required torque, ft.-lbs. 7.6 14.8 19.0 Machine tool: Okuma & Howa vertical machining center area of uncut chip is more accurate than the estimations Machine’s nominal power: 30 hp provided by other methods. Type of drive: Direct drive The author developed a new method for performing such Spindle taper: CAT 40 calculations, as well as the formulas, which are described in Machining parameters for roughing operation: his book, “Engineering Formulas for Metalcutting.” DOC: 0.375" The most common method of calculating machining power WOC (W): 2.0" is based on the mrr and a specific power, which is also known Spindle speed (n): 10,000 rpm as p factor or power constant. Published power constant Feed rate (F): 300 ipm data may vary significantly and is usually overestimated, Based on this data, the author performed the following sometimes by more than 40 percent. Specific power in mill- routine calculations to determine whether or not this rough- ing for all aluminum alloys recommended by “Machining Data ing operation qualifies as high-speed machining. Handbook” is 0.32 hp∕in.3∕min. It means that the required Cutting speed: machining power in this case should be: 225 in.3/min. × 0.32 VC = (π × D × n) ÷ 12 = 5,236 sfm hp∕in.3∕min = 72 hp. Metal-removal rate (mrr): All necessary step-by-step calculations of required machin- 3 Q = DOC × WOC × F = 0.375 × 2 × 300 = 225 in. /min. ing power are omitted. Calculations were performed for the O, Feed per tooth: T4 and T6 tempers of 6061 aluminum alloys for comparison. fz = F ÷ (Z × n) = 300 ÷ (5 × 10,000) = 0.006" The cutting force, machining power and torque are increas- The values of the cutting speed (5,236 sfm) and mrr (225 ing with the increase of the work material’s ultimate tensile 3 in. /min.) indicate high-speed machining in this application strength, depending on the type of temper (see table). at a high-productivity level. However, the maximum produc- The required machining power of 38 hp for rough milling tivity from a given machine is achieved when the required of 6061-T6 aluminum alloy at the selected cutting conditions machining power—in a long run—is about the same as the exceeds the Okuma & Howa’s nominal power of 30 hp by 27 machine tool’s nominal power. percent. Rovema’s Keifer confirmed that the machine tool’s Required machining power can be calculated through the power meter has shown that power consumption was higher tangential cutting force and the cutting speed. Calculating than 100 percent, adding that this VMC can run at up to a the tangential cutting force through the ultimate tensile 150 percent load for 30 minutes without any problems. strength of the workpiece material and the cross-sectional —E. Isakov Mechanical properties, such as hardness and strength, are lowed by one or more digits. The first digit (1, 2 or 3) indi- low. Therefore, grades with 99 percent or more aluminum cates the specific sequence of basic operations. are not suitable to be machined as workpiece materials, but n H1 (strain hardened only) applies to products that aluminum alloys are. After steel, aluminum alloys are the are strain hardened to obtain the desired strength without most machined material. Temper Designation Grades with 99 percent or more aluminum The temper designation system is based on the sequences are not suitable to be machined as of mechanical or thermal treatments, or both, to produce the various tempers, which include the basic tempers and workpiece materials, but aluminum alloys subdivisions of basic tempers. are. After steel, aluminum alloys are the Basic temper is designated by a capital letter. most machined material. n F (as fabricated) is applied to products when the me- chanical property limits are not specified. n O (annealed) indicates products that have been an- supplemental thermal treatment. nealed to obtain the lowest-strength temper. n H2 (strain hardened and partially annealed) pertains n H (strain hardened, applied to wrought products only) to products that are strain hardened more than the desired indicates products that have been strengthened by strain strength and then reduced in strength to the desired level hardening, with or without supplemental thermal treatment by partial annealing. Aluminum alloys’ strength and hard- to reduce some strength. ness are imparted through strain hardening, whereas partial n T (solution heat-treated) applies to products that have annealing reduces hardness. Because a metal’s strength is been strengthened by heat treatment, with or without subse- directly proportional to the hardness, a decrease in hardness quent strain hardening. results in lower strength. Subdivisions of basic tempers are applied to strain-hard- n H3 (strain hardened and stabilized) applies to products ened (H) and solution heat-treated (T) products. that are strain hardened and whose mechanical properties Strain-hardened designations consist of the letter H fol- are stabilized by a low-temperature thermal treatment. Additional Temper Designations strengths of 5052-H34 (38,000 psi) and 5052-H36 (40,000 A number from 1 through 9 following the designations psi), so the estimated tensile strength of 5052-H35 alumi- H1, H2 and H3 indicates a degree of strain hardening—a num alloy is (38,000 + 40,000) ÷ 2 = 39,000 psi. two-digit H temper. The number 8 indicates tempers with To identify a variation of a two-digit H temper, a third ultimate tensile strength equivalent to that achieved by cold digit (from 1 to 9) may be assigned, and presently digits reduction at a temperature not exceeding 120° F following 1, 2 and 3 are in use. A three-digit H temper is used when full annealing. For example, actual tensile strength of 5052- the mechanical properties are different from but close to H38 aluminum alloy is 42,000 psi. The number 9 designates those for the two-digit H temper designation to which it is tempers whose minimum ultimate tensile strength exceeds added. that of the 8 temper by 2,000 psi or more. n With Hxx1, the third digit applies to products that are Aluminum alloys having an ultimate tensile strength ap- strain hardened less than the amount required for controlled proximately midway between that of the zero (annealed) Hxx tempers. As previously mentioned, the first “x” is a temper (actual tensile strength of 5052-O aluminum alloy is digit from 1 to 3, and the second “x” is a digit from 1 to 9. 28,000 psi) and the 8 temper are designated by the number For example, ultimate tensile strength of aluminum alloy 4 [actual tensile strength of 5052-H34 is 38,000 psi; calcu- 5083-H321 is 46 ksi and that of aluminum alloy 5083-H32 lated value is (28,000 + 42,000) ÷ 2 = 35,000 psi].
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