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Aluminium

Introduction to Aluminium

Aluminium is a lightweight and highly machinable material, but its softness and tendency to generate built-up edge (BUE) present unique machining challenges. Without the right tooling, poor chip evacuation, tool wear, and material adhesion can lead to reduced tool life and surface finish defects. Aluminium’s thermal conductivity and corrosion resistance make it a common application in heat exchangers, electrical products, and precision components.

Exactaform’s PCD, carbide, diamond-coated, and HSS cutting tools are engineered to prevent BUE, optimise chip control, and enhance cutting efficiency. Our advanced tooling solutions ensure accurate drilling, improved machining processes, and extended tool life. Whether machining structural aerospace components, high-speed automotive parts, or industrial engineering applications, our cutting tools deliver high precision, maximum process stability, and optimal material consumption.

By addressing the challenges of aluminium machining, Exactaform helps manufacturers achieve better surface finishes, faster production speeds, and higher efficiency in aerospace, automotive, and precision engineering industries.

What Tool Groups Can You Use to Machine Aluminium?

Aluminium’s machinability allows for a variety of cutting tools to best suit your application requirements. Selecting the right tool ensures optimal performance, surface finish, and productivity..

PCD (Polycrystalline Diamond) Tools:

The best choice for high-speed, high-volume machining in aerospace and automotive applications. PCD tools offer superior wear resistance, precision, and extended tool life, making them ideal for demanding production environments.

Carbide Tools:

A durable and cost-effective solution for general machining, capable of handling a wide range of cutting conditions across various industries. These tools provide consistent performance in both high-speed and conventional aluminium alloys.

High-Speed Steel (HSS) Tools:

Ideal for low-speed machining, prototype work, and general engineering applications. HSS tools perform well in unstable cutting conditions, particularly when machining conventional aluminium alloys.

By selecting the right tooling solution, manufacturers can achieve higher machining efficiency, improved surface quality, and enhanced material consumption management in industrial and commercial applications.

What Would You Use Aluminium as a Material For?

Aerospace Applications:

Aluminium is widely used in aircraft manufacturing due to its high strength-to-weight ratio, lightweight properties, and fatigue resistance. Its high machinability and thermal conductivity make it essential for structural components that require durability and efficiency. It is commonly used for:

  • Wing Skins, Panels, and Ribs:
    Providing structural integrity, acting as an excellent conductor of heat, and reducing aircraft weight.
  • Stringers and Flying Controls:
    Ensuring mechanical strength, aerodynamic efficiency, and long-term performance under high stress conditions.
  • Landing Gear and Structural Components:
    Offering durability under extreme conditions, improving impact resistance, and withstanding high loads in aerospace environments.

Automotive Applications:

With the push for lightweight vehicle manufacturing, aluminium is a key material due to its heat-treatable nature, excellent conductivity, and alloying versatility. It plays a critical role in:

  • Turbohousings and Pumphousings:
    Enhancing thermal conductivity, efficiency, and engine performance in high-temperature applications.
  • Cylinder Heads and Gearbox Housings:
    Providing durability, heat dissipation, and mechanical strength, making them ideal for high-performance engines.

Aluminium’s recyclability, crossover aluminium alloys, and iron alloy compatibility make it essential for precision engineering, contributing to fuel efficiency, performance, and sustainability across the aerospace and automotive industries.

Why Would You Choose Aluminium Material? What Are Its Properties?

Aluminium is chosen for machining due to its exceptional material properties, making it a preferred option for lightweight, high-performance parts. Its low density reduces overall component weight, improving fuel efficiency in aerospace and automotive applications. As a light metal with high thermal conductivity, aluminium is widely used in heat exchangers, electrical conductor components, and cooling systems, ensuring efficient heat dissipation in engine and battery systems.

With a high strength-to-weight ratio, aluminium is a key material in electrical products and industrial production, offering excellent wear resistance, chemical stability, and corrosion resistance. Its superior electrical conductivity makes it essential in power grids, electronics, and energy storage systems, further increasing its industrial demand.

Aluminium is also non-magnetic and non-sparking, making it suitable for specialised applications where airtight and watertight properties are required. Its impermeability ensures that components remain sealed and protected, enhancing durability across a variety of industries. Additionally, aluminium’s malleability allows for complex part designs without compromising structural integrity, making it an ideal choice in precision machining and high-performance manufacturing.

Bespoke Tooling Solutions for Aluminium

Exactaform provides bespoke tooling solutions for aluminium machining, offering PCD, carbide, diamond-coated, and HSS specials designed to maximise efficiency, precision, and tool life. Our tooling includes drills, mills, countersinks, reamers, but we manufacture a wide variety of tools to suit different applications. Alongside bespoke solutions, we also offer standard high-performance product lines.

Why Choose Exactaform for Machining Aluminium?

For over 45 years, Exactaform has been at the forefront of cutting tool innovation for complex materials, specialising in PCD solutions for high-performance aluminium and other MMC machining. Our technical team provides expert advice to ensure maximum efficiency, precision, and tool life for demanding applications.

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