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How to avoid deformation in aluminum machining

by Joseph Mireles

One of the most famous industrial raw materials we have is aluminum. However, the reason why most people keep seeking tips to reduce aluminum deformation is due to its hard nature which is often prone to spoiling especially when put in thin plate parts. When it comes to aluminum machining, you must ensure that the aluminum remains in a shape.

Bearing this in mind, we have come up with some of the key steps to ensuring that the aluminum retains its performance. Let’s get to it!

1. Symmetrical machining

If your aluminum tends to process faster, you will need to avoid keeping it in a massive heat concentration. This is fine to create a better room for heat dispersal which in turn helps to get rid of thermal deformation. To achieve this, you will need to employ the symmetrical processing method. When this method is implemented, the aluminum stands a lower chance of getting deformed.

2. Choose the right cutting parameter

In aluminum machining, you can reduce the force of cutting but right choosing the cutting parameter (s). If you’re involved in the mechanical process and you find out that the cutting parameters are larger than they should expect the cutting force to become excessive. Once it becomes excessive, this easily leads to the deformation of aluminum parts.

So, you need to dedicate your time to choose the right cutting parameters or risk having the aluminum lose its durability.

3. Layered multiple machining

If there are several cavities in the allot plate parts of the aluminum, then it’s simpler to join the cavity wall. This is because of the uneven force it comes with. One of the best ways to cure this problem is by using the layered multiple machining technique. This method helps you to process the cavities all at once.

The aluminum parts can be sections into multiple layers and processed according to these layers. The force applied while the processing is going ok helps to reduce the risk of deformation.

 4. Application of different approaches

If you’re using the rough cutting and finishing method, you will need to apply a variety of approaches. For rough cutting, you will need to remove any extra material that lies on the empty surface in a space of a few minutes. Ensure to maintain a fast cutting speed while forming the needed finishing (geometric contour).

For the finishing method, you will need to maintain high accuracy while machining. The success of this technique is the quality of milling.

5. Drilling and milling

While milling, you may need to avoid applying the milling cutter directly on the parts of the aluminum. If not, you may end up having a rough cut as a result of insufficient wreckage of the cutter. This further causes the large accumulation of excessive heat while cutting and also, the breaking of the knife.

One way to effectively drill and mill in aluminum is to pre-drill and then mill.


Preventing or reducing the deformation of aluminum machining is necessary. We have outlined the necessary tips that would prove to be helpful when you need it.

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