How to Square Large Aluminum Blocks with a Duplex Milling Machine

First rough mill four faces, leave 0.3~0.5mm margin; clamp use flat mouth vise plus parallel pad, guarantee datum face paste solid.

Spindle rotation speed 1200~1800rpm, feed 0.05~0.1mm/tooth.

Then fine mill adjacent two faces, adopt align tool find correct, control perpendicularity ≤0.02mm/100mm, finally mutual inspect correct.

Material Preparation and Pre-Inspection

Dimensions & Processing

In 22 degrees constant temperature room put good aluminum block is hoisted by overhead crane, lightly placed on machine tool work table. Masters will at bottom pad on several pieces hardness reach HRC58 special use pad iron, interval about 300 millimeters. Pad iron's thickness difference is stuck extremely strict, absolutely not exceed 0.005 millimeters, tiny suspension all will let machine when cutting shiver. 5 tons load bearing limit nylon hoist belt slowly descends, operator steadies edge corner prevent aluminum block bump knock pad iron.

Before tighten side hydraulic jaw mouth, worker takes torque wrench take position block twist to 45 Newton meters. This strand force path if deviate big, straight aluminum plate middle just will arch up 0.15 millimeters. Spindle change on eccentric photoelectric edge finder, every minute turn 600 circles, slowly toward aluminum block side face lean. Edge finder probe touches edge, built-in 24 volt red LED light lights up, control board's X axis coordinate clear zero, operator toward inside move 2.5 millimeters fix good down tool origin.

Double face milling machine on installed two pieces large size fly cutter head. Master presses drawing list one by one check first pass rough processing's five items parameters:

· Cutter head outer ring dimension: diameter 250 millimeters

· Blade material category: no coating PCD diamond

· Blade install angle: direct front incline 15 degrees

· Cut tooth mouth quantity: 12 tool teeth surround into one circle

· Wear replace boundary: blade back face wear 0.2 millimeters

Control console press down green start key, two sides spindle rotation speed soar to every minute 2800 revolutions. 1.5 megapascal high pressure's cooling water with every minute 150 liters flow rate wash toward cutter head, take metal friction produce 300 degrees high temperature rapidly wash scatter. Two sides milling heads from left right two ends opposite direction close up, single side cut drop 1.8 millimeters thick surface aluminum skin.

Thickness 0.15 millimeters silver white aluminum chips fall into bottom's crawler chip conveyor, every minute 1200 millimeters feed tool speed lets rough rough blank change a shape. Two sides receive force just well mutually cancel out 3000 Newtons side face thrust, workshop inside's cutting noise maintains at 80 decibels up down. Length width error has up down 3 millimeters rough blank, few minutes inside is cut get only compare drawing more out 0.5 millimeters.

Operator takes 0.6 megapascal pressure air gun blow clean table surface on gap, loosen side on large size hydraulic fixture. Fixture loose drop's instant, corner on erected lever dial indicator pointer toward back jump move 0.02 to 0.08 millimeters. This piece faded skin's half finished product needs at workshop floor tile on peacefully silently put full 4 hours, bottom part pad 20 centimeters high wood strip keep ventilation.

Quality inspector takes notebook measure calculate several groups numbers, come look material inside's tight taut feeling has not has scatter exhaust:

· Just cut finish's stop put time: full hit full calculate 4 hours

· Loosen fixture's natural deformation: every meter not reach 0.05 millimeters

· Second time clamp tight's hydraulic strength: compare rough processing time small 30%

· Surface residue cooling water's temperature: with room temperature same be 22 degrees

This time tool head only cut enter go 0.3 millimeters, cooling water's mix ratio concentration from 5% tune high to 8%, acid alkali degree measure come out is 8.5, touch up come even more slippery hand. Spindle rotation speed raise arrived every minute 3500 circles, feed tool speed put slow to every minute 800 millimeters.

Length width dimensions away from drawing requirement only short 0.1 millimeters margin. Master holding 0 to 2000 millimeters measure range vernier caliper, use about 15 Newtons thrust force stuck two sides measure. Front reverse two faces' flatness error is repaired arrived 0.015 millimeters inside. Receive tail processing before, operator at cutter head on changed two pieces bring 0.5 millimeters wide wiper edge's special blade.

These two pieces blades compare other ordinary blades high out extremely tiny 0.03 millimeters. Tool tooth every time only toward front walk 0.05 millimeters, feed speed drop to every minute 500 millimeters, whole cutter head steadily sweeps pass whole piece aluminum plate. Single side only cut drop 0.05 millimeters thickness. Powder shape fine micro aluminum foam along water flow wash into bottom part's three stage filter net.

Quality inspector holding roughness meter at top face slide pass go, probe walk pass 2.5 millimeters sample length, screen on Ra numerical value steadily stops at 0.8 to 1.2 micrometers between. Length width height dimensions completely stuck at positive negative 0.02 millimeters deviation inside. Finished product placed at marble inspect measure table on use dial indicator measure opposite face parallelism, meter needle shake move even 0.01 millimeters all not reach.

Workshop inspect measure table front, three coordinate measure member one strip one strip check account release go:

· Single side absolute dimension deviation: positive negative 0.02 millimeters

· Two strips diagonal line length difference: not reach 0.05 millimeters

· Adjacent two faces' perpendicularity: every 300 millimeters deviate 0.015 millimeters

· Surface roughness meter reading: Ra 0.8 to 1.2 micrometers

· Edge corner pour round processing: 0.2 millimeters multiply 45 degrees micro chamfer

This piece 1205 millimeters long, 805 millimeters wide, 155 millimeters high saw cut rough blank, shed body change bones became long 1200.00 millimeters, wide 800.00 millimeters, high 150.00 millimeters square upright metal block. Worker takes dust free cloth dip 10 milliliters will volatilize rust prevent oil, at six bright faces on wipe one layer thin film. Four edge corners' surplus material drop fall whole whole 2 millimeters thickness.

This layer thin film can separate open machine processing workshop air inside 65% moisture gas, let flat level aluminum face in 24 hours inside not grow out white spots. Package personnel pick up 5.0 millimeters thick pearl cotton take six faces wrap strict solid, use high viscosity tape wind on three circles thoroughly seal dead. Wrap good finished product piece weight reach 380 kilograms, by 3 tons load weight hydraulic earth cow drag toward hole position processing area, wait drill cut thirty several thread bottom holes.

Deburring & Surface Cleaning

Band saw machine sharp saw blade will at aluminum block up down two sides leave down thickness at 0.5 to 1.5 millimeters turn edge burr. Worker must wear on prevent cut level reach 5 level nitrile gloves, use hand along edge touch one circle. Flesh eye looking not obvious saw tooth grain, can easily scratch break ordinary cotton thread gloves.

Master hand inside grips one piece rotation speed every minute 22000 revolutions pneumatic chamfer machine. Connect on 0.6 megapascal pressure air pipe, tungsten steel material rotate file tool head press against aluminum block ridge edge. Along about 800 millimeters long edge push pass go, aluminum chips like fine sand same spray come out. Originally prick hand right angle edge, immediately became one strip 2.0 millimeters wide, include angle 45 degrees smooth incline face.

Machine care not reach's four dead corners, must rely hand work processing. Old master draws out one piece long 300 millimeters, surface cloth full 150 mesh texture's half round file. Two hands hold file two ends, press down about 30 Newtons force path, present 15 degree angle toward front push file three to five down. Corner inside residual 0.2 millimeters small hard lump is thoroughly grind flat, absolutely not give follow up install clamp leave any hidden danger.

File walk pass edge's time, master's eyes tight stare just expose bright color metal layer. Band saw cut break time feed tool too fierce, material edge corner occasionally will tear split out depth about 0.5 millimeters dark grain. Meet flesh eye just can look clear crack thread, must use pneumatic polish machine change on 80 mesh sand cloth wheel, toward inside deep dig at least 1.0 millimeters.

Edge corner processing finish, aluminum block surface scatter drops large amount fine micro metal powder. Workshop wall on pull over one root diameter 8 millimeters PU air pipe, air gun spray nozzle leave metal surface keep 5 centimeters distance. 0.8 megapascal high pressure air flow present fan shape sweep pass, take hide in saw cut grain path inside micrometer level aluminum ash all blow fly.

Dust powder gone, metal face on still cover one layer band saw machine leave down saponification liquid. Thickness not reach 0.01 millimeters oil film if not wash drop, will large amplitude pull low fixture's friction force. Worker lift come one piece install full 5 liters industrial degrease agent plastic bucket. Transparent liquid's volatilize speed is ordinary water's 8 times, can in 10 seconds inside bring walk sticky thick oil dirt.

Tear down two pieces dimensions about 300 multiply 300 millimeters dust free wipe cloth, spray on about 20 milliliters degrease agent. Along long edge direction, apply about 2 kilograms press force path, come back wipe three passes. Wipe cloth surface immediately float up one layer grey black oil mud. Aluminum block originally emit dark metal bottom color begins reflect light.

Meet solidifying rust prevent oil block, must change on purity 99.9% isopropyl alcohol solution. Pour out 5 milliliters drip at stubborn dirt stain on, wait on 5 seconds let liquid completely soak through. Worker takes hardness relative low brass scraper tool light light one push, oil block whole piece peel drop. Take one piece dry new test paper paste up go, press down 10 seconds after tear down, paper face cannot have one tiny bit oil print.

Polyester fiber dust free cloth wipe finish third pass, suck full solvent and oil dirt, weight from original 5 grams increase near one time. Operation worker takes dirty wipe cloth throw into special use bring cover garbage bucket, stick full degrease agent cloth material must isolate keep put. Just wipe finish aluminum plate surface still bring micro weak smell, workshop top part's exhaust fan with every minute 800 cubic meters exhaust volume rapid pump air.

Smell in short short 15 seconds inside scatter exhaust, naked expose metal face use hand back touch up go reveal one thread cool intent. Aim at go burr and wipe these two strips extremely consume artificial labor work, workshop craft list on stuck three strips dead orders:

· Chamfer parameter set: pour blunt width at 1.5 to 2.0 millimeters between, incline face angle keep 45 degrees, deviation tolerate at positive negative 0.2 degrees.

· Clean tool require: forbid use drop hair cotton material wipe cloth, must adopt suck water rate reach 250% polyester fiber dust free cloth.

· Degrease agent ingredient monitor: PH value must control at 7.0 to 7.5 neutral range, acid alkali degree exceed standard will bite hurt aluminum alloy surface.

Organize get clean clean aluminum block, surface friction coefficient happen turn sky over earth change. Hydraulic clamp jaw bite close time, clean degree relates to metal block will not will at several hundred kilograms cutting force under produce slide move. Quality inspector body follow bring test equipment, special use to issue out clean front after compare number list:

Check inspect finish table on data, worker takes one piece clean white board wipe at processing face on use force rub two down. White board wipe bottom part's snow white fluff wool stick not up any grey spot, this strip work sequence only allow sign word hand over work. Operate table side's temperature humidity meter show current relative humidity is 45%, just volatilize finish degrease agent aluminum block surface temperature drop down about 0.5 degrees.

Flatness & Warpage Assessment

One piece long 2500 millimeters, wide 1500 millimeters, thickness reach 300 millimeters Jinan green marble inspect test platform place at workshop center. This piece 00 level granite flat board experience pure hand work grind, surface every square meter high low drop fall is dead dead stuck at 0.005 millimeters inside. Room temperature constant year control at 22 degrees, prevent marble table face heat expand cold shrink happen physical shape change.

Put aluminum block before, quality inspector takes no water ethanol take marble table face come back wipe three passes. One tiny dot 0.05 millimeters thick dust powder particle pad at bottom under, all will let behind measure calculate whole plate report error. Nylon hoist belt drop to bottom, master stretch hand fierce push aluminum block diagonal line position. Two ends curl up metal plate at stone face on emit out heavy dull bump knock sound.

6061 material plate at band saw machine cut break after, inside residual stress thoroughly let fly. Look like four flat eight stable aluminum block, surface tension lose balance, every meter length at least arch up 1.2 millimeters bend arc degree. Worker from wood box inside dig out one piece bring have 20 pieces steel pieces feeler gauge. Most thin blade only has 0.02 millimeters, thick one point has 0.50 millimeters, surface coat full rust prevent machine oil.

Master uses cotton cloth wipe dry steel piece on oil, draw out mark with 0.15 millimeters scale that piece, stick marble toward aluminum block bottom under gap inside fierce stuff. Steel piece without resistance slide enter inside side, probe straight poke arrived 80 millimeters deep position. Change on 0.50 millimeters thick steel piece toward inside probe, push enter go about 30 millimeters just feel is raw hard stuck hold.

Meet feeler gauge stuck pause dead corner, master takes marker pen at aluminum block side edge draw one strip long line, side by side crooked twisty mark on "0.5" words. Along 1200 millimeters long edge line stroll one circle, four strips edges full full mark out seventeen eighteen different thickness numbers. Measure finish surrounding still must look belly, take one root long 1500 millimeters knife edge steel straight ruler horizontal cross aluminum block top face.

Straight ruler middle's bottom part obvious suspend empty, reveal out opposite face miserable white LED workshop light light. Thin feeler gauge again upper battle, several sheets leaves stack together toward ruler bottom under try probe. Right middle gap measure come out reach whole field biggest 1.85 millimeters. Weight reach several hundred catties aluminum material now's shape, like extremely one sheet is sun shine dry micro curl edge big tree leaf.

Measure out come specific error data, is one pen one stroke register record enter inspect measure table list:

· Four edge corners suspend empty extreme value: left up 1.25 millimeters, right down 1.50 millimeters

· Long short edge middle paste close gap: long edge zero gap, short edge 0.80 millimeters

· Top face center position down dent amount: local extreme limit reach 1.85 millimeters drop fall

Hand inside holding data table, quality inspector touch up red marker pen at aluminum block middle draw one big big cross mark. One face four surroundings curl up, middle dent trap bottom is determine as "datum face B". Turn over 380 kilograms aluminum block, at like turtle shell same bulge up back part draw on circle, mark become "processing face A". Up machine tool install clamp time, according to rule take draw cross dent face toward down press at pad iron on.

Hard press bend rough blank is machine processing big taboo. 100 kilonewtons hydraulic jaw take bulge face toward down dead dead press at work table on, look like board straight. Wait cutter head cut flat top face, loosen fixture leak drop pressure instant, metal inside clip bring bend memory reverse bounce, just mill flat surface immediately bend back 1.5 millimeters arc degree.

Along natural bend degree walk, bottom face gap cannot empty up machine. Install clamp master press according to measure out 1.85 millimeters drop fall, go tool box turn find different thickness purple copper pad piece. Pick out two pieces 0.80 millimeters, one piece 0.20 millimeters outside plus one piece 0.05 millimeters thin copper piece stack together. This stack thickness gather complete 1.85 millimeters copper piece, is stuff enter aluminum block bottom part biggest suspend empty place.

Remaining edge gaps exceed 0.10 millimeters place, one by one use 0.05 to 0.15 millimeters thickness yellow copper paper pad get strict strict solid solid. Four corners pad finish, master two hands grab firm weight reach 380 kilograms aluminum block edge use force shake sway. Metal block lie at double face milling machine cast iron work table on grain silk not move, even 0.01 millimeters shake sway gap all try probe not out.

Spindle suck plate on erect up one piece lever dial indicator, row check final surface extreme difference. Meter head diameter 2 millimeters red jewel measure micro head press at aluminum block edge highest point, operator turns meter circle take pointer return zero. Press down panel button, spindle push dial indicator stick aluminum plate surface horizontal direction walk pass 800 millimeters. Meter plate pointer one road from zero deflect turn arrived 1.95 millimeters position.

1.95 millimeters extreme value number, record whole piece plate material warp bend degree bottom line. Operation worker at control panel on take left right double faces first tool eat tool depth input as 2.5 millimeters. Leave out 0.55 millimeters rich surplus amount, can let big diameter cutter head one time take highest point and dent trap place oxidize skin all scrape clean. Machine tool thick heavy prevent explode steel transform glass door slowly close up.

Machining Face

Tool Parameters

Mill cut big piece aluminum material end face, double face spindle on install cutter head size very big, diameter usually at 250 millimeters or 315 millimeters.Cutter head body use aviation aluminum or high strength tool steel manufacture, run turn before must do dynamic balance, require reach G2.5 25000 revolutions level. Spindle even if have one bit deflect swing, centrifugal force one pull tear, exceed 0.005 millimeters error will destroy surface flat level degree.

Blade front face's front angle made into 20° to 25° incline, edge mouth extremely thin, blunt round radius not reach 0.02 millimeters. Back face's back angle leave at 11° to 15°, let tool bottom and aluminum block surface less friction. Blade front face polish get like mirror, roughness stuck at 0.05 micrometers below, aluminum chips at top face smooth slippery slip walk, will not stick knot emit heat.

· K10 no coating hard quality alloy resist bend strength 2500MPa

· 0.8 micrometers micro crystal grain prevent edge mouth receive force collapse break

· PCD poly crystal diamond micro display hardness extremely high reach 8000HV

· Diamond coating thickness thin to only 0.5 millimeters

· Blade back face use 0.01 millimeters micro small chamfer add solid

Rough processing time, machine turn get fly fast, cut speed push to 1500 meters/minute full load run. 250 millimeters cutter head one minute turn near 1900 circles, every tool tooth every turn one circle eat drop 0.25 millimeters aluminum. Blade one breath qi can pierce enter aluminum block 4.5 millimeters deep, one minute just can gnaw down 3500 cubic centimeters waste material. Two sides spindle same time face toward cut, horizontal direction thrust force break through 12 kilonewtons, take machine tool Z axis silk rod press get dead dead.

Fine processing completely changed one kind cut method, one tool only cut 0.15 to 0.2 millimeters extremely thin one layer. Speed soar get more fast, reach 2200 meters/minute, spindle turn speed approach near 2800 revolutions. Every tooth's feed give amount drop to 0.08 millimeters, big cutter head turn whole whole one circle only toward front walk 1.2 millimeters. Big cutter head on install 12 to 16 pieces ordinary blades, gap inside still will special stuff enter 1 to 2 pieces wiper edge.

Wiper edge compare ordinary blade little micro bulge out come 0.03 to 0.05 millimeters. It most front face has one section 2.5 millimeters wide flat straight tool edge, like one piece iron iron same wipe pass surface. At extremely small feed give amount cooperate under, this section flat straight tool edge take ordinary blade leave down micro small wave valley all wipe flat. Process finish surface can reflect out person shadow, roughness 0.4 micrometers, every meter length flat level degree error not reach 0.008 millimeters.

· Spindle center spray out 50 Bar high pressure cooling water column

· Cut liquid every minute circulate wash brush whole whole 80 liters

· Water and oil according 9:1 precision accurate mix into micro emulsify liquid

· Aluminum chips are force force wash break into 25 millimeters long C shape

· Row chip machine every hour pump walk 400 kilograms solid state waste aluminum slag

Cutter head on blade purposely install get sparse dense not one, adjacent blades include angle difference 2° to 3°. This kind not symmetry design directly strike disorder vibration frequency, cut sound became 85 decibels heavy dull hum hum sound. Install blade extremely strict, master takes dial indicator one by one measure, jump move error dead bump at 0.003 millimeters inside, up screw unit use 3.5N·m fix torque wrench twist tight.

Tool point cut enter aluminum block that one instant, temperature in 0.01 seconds inside soar raise to 450°C. PCD blade guide heat coefficient high reach 560 W/(m·K), heat amount swish ground one down just along tool body pass walk. 80% high temperature all leave in cut break aluminum chips inside, instant is high pressure cut liquid wash fly. Remain under that point heat amount root basic wear not through 0.15 millimeters fine processing layer, thick heavy aluminum block inside part still old keep 22°C to 25°C room temperature state.

Rough Mill & Fine Mill

Double face milling machine two sides spindle together emit force, every side's single side eat tool amount set determine at 3.5 to 5.0 millimeters. Two pieces giant type plane tool two faces clamp strike, take original thickness 400 millimeters aluminum block instant cut decrease drop near 10 millimeters. Two pieces cutter head's turn speed steady at 1500 revolutions/minute, feed give speed push to 1800 millimeters/minute.

Rough processing stage cut force extremely big, single side thrust force exceed 12 kilonewtons. Operator take hydraulic fixture's pressure meter pointer hit arrived 25 megapascals. 24 pieces hydraulic press boards from four faces eight directions dead dead bite hold work piece edge, apply add total calculate exceed 8 tons clamp tight force. Huge force path guarantee cutter head crazy gnaw bite aluminum material process middle, work piece at work table on even 0.01 millimeters position move all will not happen.

Big lump head material is rapid cut produce explode out shock person's heat amount, cut area temperature in 0.5 seconds inside rush break 400 degrees. Machine tool self bring high pressure water pump full speed run turn, every minute take 120 liters concentration be 8% emulsify liquid smash toward two pieces cutter head. Fly splash out come aluminum chips like violent rain same scatter drop, short short 15 minutes can at machine tool bottom plate pile up half meter high, weight reach 30 kilograms silver color metal waste material.

Surface skin is peel drop aluminum block inside original accumulate press cast make stress begins release, material happen flesh eye look not see twist bend shape change. Absolutely cannot hurry to change tool continue cut, must let spindle stop turn, take 25 megapascals clamp tight force drop to 0. Operator takes air gun blow clean bottom seat on water stain and residue aluminum slag. Take off heavy press aluminum block needs at room temperature under still put whole whole 5 minutes, wait inside part fiber completely natural stretch expand.

Wait aluminum block thoroughly release finish pressure, hydraulic fixture re new start move, this time pressure numerical value large amplitude shrink decrease. Pressure meter pointer stop at 6 megapascals position, clamp tight force drop arrived not reach 2 tons, just just good paste tight dead dead fix reside aluminum block edge. If is continue use 8 tons force path press hold it, fine processing finish one loosen fixture, flat level surface immediately like spring same reverse bounce pop out 0.05 millimeters error, front face's work all waste.

Re new clamp good after fine mill work sequence formal up field, two sides need cut drop thickness only remain down 0.15 to 0.2 millimeters. One layer compare two roots hair thread still must fine surplus amount, need cutter head use 2800 revolutions/minute high turn speed light light sweep pass. Feed give speed drop arrived 1200 millimeters/minute, extremely small eat tool amount guarantee solid cutter head on wiper edge can even uniform wipe flat aluminum block surface's every one inch skin flesh.

Fine cut almost will not produce many surplus heat amount, cut down come waste material became extremely thin half transparent snow flake shape broken piece. Cooling liquid pressure slightly tune low to 15 bar, water flow no longer crazy violent smash toward work piece, turn into gentle soft wash brush blade bring walk fine micro residue chips. Spindle motor load meter on show current only area area 2 amperes, spindle occupy use rate even 15% all not run arrived.

Length reach 2 meters aluminum block end face walk finish final one tool, double sides spindle slow slow retreat back two sides original position. Quality inspector takes one root 1.5 meters long marble flat ruler lean at just cut good face on, 0.01 millimeters feeler gauge root basic insert not enter gap inside. Dial micrometer at long square shape four corners respectively stuck one down, thickness dimension extreme difference dead dead control at 0.012 millimeters, process out come two faces like mirror same flat.

· Fine processing advance leave thickness strict control at 0.15 millimeters inside, leave much easy cause blade secondary squeeze press friction emit heat.

· Two sides cutter head walk tool track is set place become hundred fraction hundred horizontal level heavy join, avoid appear 0.005 millimeters above join tool step mark print.

· Cut liquid temperature through outside part cold water machine group force direct constant determine at 22 degrees, prevent water temperature raise high pass guide give work piece cause heat expand expand.

· Finish work finished product will at machine tool work table on still put cold cool 1 minute, wait temperature thoroughly and room temperature same step after again loosen open fixture.

Realize micro meter level plane level precision degree, rely double face milling machine bottom part three roots heavy type straight line roll pillar guide rail. Weight reach 4 tons raw iron work table support several hundred kilograms aluminum material at guide rail on come back slide move, friction force micro almost its micro. Even if is with 2000 millimeters/minute empty run speed rapid return back, work table final fix position precision degree still ran precise accurate stuck at 0.008 millimeters position.

Cooling Liquid & Heat Deformation

Aluminum alloy toward temperature extremely sensitive, 6061 brand number aluminum material line expand expand coefficient high reach 23.6 micrometers/meter·degree. One piece length reach two meters large type aluminum plate, process course inside temperature slightly toward up rub 5 Celsius degrees, length extreme difference will violent raise near 0.24 millimeters. Mill cutter head at cut area tear pull metal, sharp cut blade mouth and work piece crazy friction produce high heat energy can in zero point several seconds inside take local part temperature push raise to 400 degrees above.

Heat amount along aluminum material extremely excellent guide heat net network rapid toward deep layer spread extend, original four four square square whole piece aluminum rough blank will like just out stove bread same toward outside bulge expand. Bring heat expand expand state process out come outside shape dimensions, wait work piece down machine move enter workshop natural cold cool to 22 degrees environment temperature, metal cold shrink effect will let end face immediately dent trap down go.

Press system heat expand expand heavy task fall at machine tool side side industrial cold water machine group on. One machine power rate 15 kilowatts independent cold water equipment whole heaven climate continuous axis turn, compress machine take bottom under water tank inside full full 800 liters emulsify liquid temperature force direct anchor determine at 20 Celsius degrees. Temperature probe needle every second inspect measure three times water pool water temperature, up down float move extreme limit error is dead dead stuck in 0.5 Celsius degrees red line inside.

Even if cut produce heat wave again fierce violent, 20 degrees constant temperature cooling liquid waterfall also can take aluminum block surface temperature force direct press press at room temperature base standard line on.

Double face milling machine enter eat tool state, two machines big power rate high pressure water pump side side row emit out low roar, spindle inside cold system full speed pump water. 120 liters/minute huge flow amount transform make two strips high pressure water columns, along spindle inside part center hole fierce violent spray shoot to cutter head tool point place. Water flow meter plate pointer steadily press at 50 bar scale degree on, crazy violent water dash strike force take stick full high temperature half melt transform aluminum chips instant smash leave cut area.

Scale degree tube inside part divide boundary line face direct 8% numerical value, water and high purity cut oil at stir mix under mix unite become number with ten hundred million calculate fine micro oil drops. Diameter not reach 2 micrometers emulsify oil drops at aluminum material surface extreme speed pave spread, form complete one layer extremely thin run smooth isolate barrier film, blade and aluminum block hard bump hard friction interfere wade sharp reduce 60%.

· Cut liquid inside according ratio mix add 0.2% resist hard water disappear bubble agent, stop block 50 bar water pressure excite up full sky bubble mask block worker sight line.

· Water pump suck water mouth filter net eye precision degree dense reach 20 micrometers, dead dead intercept block down extremely fine small aluminum powder particles.

· Cutter head outside circle surround one circle 6 roots universal cooling spray pipe, every root pipe out water amount fix determine at 15 liters/minute.

· Is cut break C shape roll chips lock reside 80% high heat amount, leave open tool blade extremely short time inside is water flow force direct drop reach 30 degrees below.

High strength degree cold water not only give aluminum material strong force drop temperature, also is at protect double face milling machine several ten millions geometry precision degree bottom plate. Weight reach 12 tons machine tool cast iron bed body long time is spread emit heat air aluminum chips pile accumulate cover over after, metal base body material same will happen local part heat warp bend. Workshop top part hang infrared line measure temperature meter time moment sweep describe down face work table, machine tool left right two sides any one piece area temperature raise difference amount is strict control at 2 degrees inside.

Bed body two sides lay set special belong to bottom seat wash brush row pipe, every separate 30 seconds big mouth diameter spray out large amount constant temperature clear clear cooling water. Several thousand pieces roll burn waste aluminum chips just fall drop at bottom part guide rail prevent protect steel plate on, immediately is surge out rapid flow seat roll bring enter side edge row chips trough. Not reach 0.5 seconds time difference, spread emit high temperature waste material is force direct clear retreat out machine tool main cavity body, one thread heat air also don't think toward Z axis heavy type stand pillar on run.

Thick heavy rough blank send up machine tool work table open cut before, must at open start 22 degrees constant temperature air condition workshop ground table quiet quiet lie full 24 hours. Ice cold metal square block is machine process workshop constant determine room temperature thoroughly pierce through, surface layer skin board temperature and inside part deep layer body temperature reach hundred fraction hundred one cause. Operator holding paste piece type measure temperature meter press at aluminum block most center position test measure, screen show 22.1 degrees reach standard read number just go press move green color start move key.

Bring room outside 30 degrees high temperature surplus heat rough rough blank hard pull up machine tool cut, down machine after natural shrink water shape change error enough to let whole batch sky price material all complete report waste.

Fine mill walk tool stage cooling liquid spray sprinkle mode thoroughly change one look appearance, 50 bar crazy violent high pressure water column reduce weak became soft gentle scatter open umbrella shape spray fog. Circulate flow amount is large amplitude shrink receive to 40 liters/minute, inside part cut oil mix ratio concentration is micro tune pull high arrived 10% top point up limit. This time use not up violent force water column wash brush big piece waste slag, thick rich thick solid run smooth oil film let wiper edge at extremely shallow surface smooth slippery slip pass.

Double sides end face processing finish complete, two sides spindle thoroughly stop turn rest drum, high pressure water pump boom sound follow it disappear stop stop rest. Worker absolutely not go touch 12 megapascals pressure hydraulic loosen clamp button, grab up side side strong wind high pressure air gun take aluminum block up down surface blow get one drop water all not remain. 22 degrees room inside cold wind at naked expose bright silver color metal face come back swim walk, bring walk final remain exist one thread micro weak cut temperature change.

Hard born born wait treat full full 120 seconds time flow pass, heavy heavy whole piece aluminum material body temperature thoroughly return fall flat steady, four sides hydraulic press board just rely sequence slow slow lift up. Aluminum block move carry to three coordinate measure machine granite flat table on still put half hour, red jewel measure head light touch process face. Computer screen temperature compensate system dead dead close at 0 set determine, report table on plane level degree numerical value steady at 0.006 millimeters, thoroughly isolate cut off heat expand expand false fake read number mix enter possible sex.

Roughing vs. Finishing

Roughing

One piece 500 kilograms heavy 7075-T651 aluminum ingot place at work table on. Machine tool two sides hydraulic clip use 12 megapascals strength take it dead dead bite hold. Two pieces diameter 250 millimeters big cutter head slow slow lean pass go. Master take operate panel on spindle rotate button directly twist to 100%.

Cutter head turn speed fix at every minute 850 revolutions, two sides together toward inside fierce cut 7.5 millimeters. Two machines motor fire power all open, consume electricity power rate one down soar to 45 kilowatts. Surface that layer 2 millimeters thick black skin is instant tear open. Cut down come's aluminum slag like down violent rain same smash at iron skin cover on.

Machine on install is APMT1604 model number blade, hard quality alloy material. Blade bring big incline angle, hard born born take aluminum block one layer one layer shovel down come. Every head on dense dense numb numb install 16 handles tools, cut run up come line speed every minute exceed 650 meters.

Sweep one eye ground on aluminum slag, old hand light look outside shape just can touch clear blade now state condition:

· Short broken C shape slag: cut get deep, row get smooth happy

· Fine long roll slag: walk tool too slow, easy wrap hold tool handle

· Emit light silver color slag: cold water pour get arrive position, no dry burn

· Change yellow bring scorch mark slag: tool point grind flat, temperature cross 150 degrees

Just down tool that while, machine tool will emit out 60 hertz low frequency hum hum sound. 8 tons heavy cast iron bottom seat rely dead heavy weight take this strand shock move dead dead press hold. Master force direct take every piece tooth feed give amount pull high to 0.25 millimeters. Machine run get more fast, heat amount just more come not in time transmit give big piece aluminum material.

About 80% heat amount all is this kind short broken slag roll walk. Aluminum block surface temperature only will raise to 45 degrees to 55 degrees. Walk tool speed if is slow than every minute 1200 millimeters, heat amount all stuffy in aluminum block inside. 7075 this kind aviation aluminum only need exceed 80 degrees, just will bulge out 0.15 millimeters shape change.

Machine tool big water pump every minute spray out 30 liters cut liquid. Mix 6% concentration water cold liquid one meal fierce wash, take stuck at cutter head on broken slag all wash drop. Water pressure must enough big, avoid exempt scatter drop slag child roll enter tool inside is secondary roll press. Only need roll enter go, hardness 150HB broken slag will at face on scratch out deep pit.

Two sides each cut drop 8 millimeters after, aluminum block inside original receive force flat balance just is thoroughly strike break. One piece 1 meter long, 50 centimeters wide board, just cut finish two ends just will toward up curl up 0.4 millimeters. Use clip can take it force direct press flat, one loosen tie immediately again bend return go.

· Motor load exceed 85% easy trigger hold back stop

· Silk rod receive force big cross 2000 Newtons will squeeze out 0.02 millimeters gap

· Water pressure not reach 2 kilograms root basic wash not walk iron chips

· Guide rail on run smooth oil film press too fierce will break crack

Take caliper one measure, away from drawing on dimensions single side much leave 1.2 millimeters. Just open finish rough surface all is deep deep tool grain, roughness at Ra6.3 to 12.5 between. Use hand touch one hold, with touch file same prick flesh.

Bring this 1.2 millimeters surplus amount and one belly inside stress aluminum block, will be push to side edge shelf on air cool. Make airplane parts, rough blank must natural put on 48 hours. Some factories use zero down 80 degrees liquid nitrogen freeze, reverse return fold toss two three times, this 0.4 millimeters curl bend just calculate thoroughly disappear stop.

16 pieces blades gnaw down 300 kilograms aluminum slag after, tool mouth will be grind flat 0.08 millimeters. Hard cut down go, block power will change big 30%. Machine tool on current meter from 45 amperes one road toward up climb, exceed 55 amperes factory inside rule must change one whole plate new tools.

Change new blades before, master holding tools one by one match exact down face these physical data:

· Up screw force moment stuck dead at 2.5 Newton meters

· Cutter head jump move error use meter measure, not exceed 0.015 millimeters

· Hydraulic clip pressure re new tune return 10 megapascals

· Cut liquid concentration meter steady at 6Brix

Water drop slow slow control dry, transmit send belt take one ground aluminum slag pour enter big iron box. Machine tool spindle brake stop, wait next one piece 500 kilograms rough blank hang up come. Heaven crane big hook slow slow drop down, electron scale on red words jump to 512 kilograms. Worker pat open green color start move key, cut continue.

Finishing

Air cool whole whole 48 hours aluminum block re new hang back double face milling machine work table. Infrared measure temperature meter hit at metal surface, screen show 22.5 degrees, with workshop inside constant temperature air condition set determine one mold exactly same. This time aluminum block inside part stress run a clean, original 0.4 millimeters curl bend amount dead dead fix live no longer return bounce.

Up one single leave down 1.2 millimeters surplus amount, now need divide two times slow slow scrape drop. Hydraulic clamp bite close force from 12 megapascals one breath qi drop arrived 3.5 megapascals. Clamp get too tight will take aluminum block strangle out micro meter level shape change, one loosen open fixture original flat level surface immediately bend out one 0.05 millimeters arc degree.

Master take two sides rough mill cutter head all tear drop down come, change on special use cut aluminum PCD poly crystal diamond blade. This material hardness reach HV6000, surface throw light arrived mirror face level, bring one 20 degree big incline angle. Touch one down tool blade, compare new buy shave beard blade still must thin, still must scrape hand.

Operate panel on parameters all push turn re new set. Spindle turn speed from 850 revolutions directly soar to 2800 revolutions every minute. Eat tool amount shrink decrease get extremely small, single side only remain down pity pity 0.5 millimeters. Take so big one machine 8 tons heavy machine cut this point thickness, exactly compare take one handle fine detail surgery knife at metal surface light light scrape one layer skin.

High turn speed match on extremely small cut amount, motor load meter on current drop arrived 15 amperes out head. Walk tool speed drop to every minute 400 millimeters, machine gone before low frequency boom hum, only remain down sharp point "hiss hiss" sound. Every piece tool tooth gnaw down come thickness not reach 0.08 millimeters, equal to ordinary print paper thickness half.

This kind run method cut out come broken slag no longer is block shape, but is like hair thread same fine soft aluminum silk. Water pump pressure is tune arrived highest gear 6 kilograms, every minute spray out 50 liters liquid. Large amount water cold liquid spray at turn move cutter head on, directly at secret close machine cabin inside smash out one big piece white color water fog.

Aluminum this kind material special sticky, temperature slightly up go to 60 degrees, that layer not reach 0.08 millimeters hair silk just will stick at tool mouth on. Emulsify liquid concentration is precision dense optics sugar degree meter measure determine at 8Brix. At every minute 2800 revolutions high speed run turn under, this can at tool and aluminum face between paste on one layer 0.2 micrometers thick run smooth oil film.

Happen stick tool, light clean aluminum face on just will be plow out one strip 0.1 millimeters deep ditch. Report waste one whole piece 500 kilograms aviation aluminum ingot, material lose fail move directly exceed one ten thousand five thousand bucks money.

First tool walk finish, original rough rough prick hand black face became float bright silver color mirror face. Take surface roughness meter touch needle paste up go scratch one tool, screen on read number steady steady stop at Ra0.8. Use finger belly light light along grain path touch pass go, feel follow touch one piece throw light good marble table face same slippery slip.

Machine stop steady, quality inspector holding one handle half meter long vernier caliper stuck live two ends. Drawing require final width is 498.00 millimeters. First time measure amount read number is 498.25 millimeters. Caliper on much out come this 0.25 millimeters, use come give final one tool slow slow grind final extreme thickness.

Measure finish dimensions still must measure temperature, surface temperature drop return 22.5 degrees just can continue cut. 1 meter long aluminum block only need temperature raise high 1 degree, length just will expand expand 0.023 millimeters. Even if only is hand at top face press half minute, human body transmit pass go heat amount all will let hundred fraction meter pointer jump move one grid.

Re new step down step board, two sides cutter head again times press up go, take this final 0.25 millimeters eat dry wipe clean. This return's walk tool speed is dead dead press at every minute 250 millimeters. Two handles cutter head slow get like snail crawl, foot foot consume 40 minutes just walk finish this 1000 millimeters long cut cut distance.

Unload carry parts even walk vehicle all dare not use fierce force, lift heavy hang belt change became wide body soft cloth material. 500 kilograms square block flat put at 200 millimeters thick granite constant temperature flat table on, begin measure calculate final geometry shape position tolerance.

· Diagonal line measure amount error is limit control at 0.05 millimeters inside

· Two ends thickness use thousand fraction ruler stuck dead, difference value cannot cross 0.015 millimeters

· Surface plane level degree take feeler gauge lean at knife mouth ruler under, 0.01 millimeters thin sheet stuff not enter go

· Four side faces perpendicularity use marble angle ruler lean, reveal not out one thread hand electric tube light

This 0.015 millimeters difference not much only have hair thread five fraction one coarse fine. Reach not arrived this number, make airplane install match parts time screw hole just thoroughly match not accurate. Quality inspector pinch feeler gauge reverse turn confirm three passes, at list on sign on words, paste on one sheet green color fit standard bar code.

Cutter head on PCD blade extremely endure grind, connect cut 50 single sides just will have 0.01 millimeters pour angle grind wear. Machine tool X axis roll pillar straight line guide rail continuous experience high precision degree micro tune friction, every run full 200 hours just must force direct hit enter 40 grams Shell run smooth yellow oil.

Work table on every one root hair thread same aluminum chips all is suck dust machine clear reason clean clean, water trough inside filter net also change one sheet new. Next one piece air cool whole whole two days half finished product is shovel vehicle push over come. Hydraulic clamp again times use 3.5 megapascals strength bite up go, screen on infrared temperature still old stuck at 22.5 degrees.