Aluminium profile machining is an industrial manufacturing process which starts with extruded aluminium bars (profiles) to produce parts with specific shapes and sizes.
The process starts with aluminium profiles, usually 6063 or 6005 alloys, which can be unfinished, lacquered or anodized. These profiles are manufactured by extrusion, where the aluminium is heated to a certain temperature before softening and being passed through a die (designed with the desired shape) while cooling at the outlet until it solidifies to match that shape.In the machining process, the profile is cut to the required length, and modified by subtractive manufacturing process until the required geometry for the final piece is achieved.
The profiles are fed into our machining machines from a loading table and are introduced to the machining and cutting area by means of a feeder. It is in this way that the bars advance at the pace of the various operations that are carried out in the machine, with continuous profiles entering and pieces of the desired geometry coming out the end. Some of the common operations, in addition to cutting, are drilling, countersinking, threading, routing, reaming, stamping, milling, etc.
Profile machining is always linked to the cutting process, since the profiles are generally manufactured in lengths of between 6 and 7 metres. To achieve the desired length of the piece, cutting discs with tungsten carbide welded teeth are used, which guarantee the necessary repeatability and precision. Depending on the complexity of the part, more processes can be added to the machining.
Six methods of machining aluminium profiles
Surface treatment (coloring)
The surface treatment of aluminum profiles improves its corrosion resistance, aesthetics and service life. Common surface treatment methods include anodizing, powder coating, electrophoresis, etc. Anodizing improves corrosion resistance and hardness by forming a dense oxide film on the surface of aluminum. Powder coating is to spray paint on the surface of aluminum to form a protective film, which is beautiful and durable. Electrophoresis uses electrolysis to form a uniform coating on the aluminum surface, which has good adhesion and corrosion resistance.
And through surface treatment, the color of the surface of the aluminum profile is also enriched. Common surface colors of aluminum profiles include: anodized silver, black, white, gold, champagne, brushed black, bronze, etc. These colors are often very popular with clients in the construction industry (windows, doors, baseboards, tile trim, LED profiles).
Cutting processing
Cutting is one of the most basic operations in aluminum profile processing. Common cutting methods include mechanical, laser, water, etc. Mechanical cutting is suitable for thicker aluminum profiles and is performed by equipment such as saws or cutting machines. Laser cutting is suitable for thin aluminum materials and has the characteristics of high precision and high efficiency. Water cutting uses high-pressure water flow to cut aluminum materials. The cutting surface is smooth and has no thermal influence, and does not cause heat to the profile.
3. Bending processing
The bending process of aluminum profiles uses a certain external force to plastically deform the aluminum profiles to achieve the required shape and angle. Common bending methods include cold bending and hot bending. Cold bending is the bending of aluminum materials at room temperature and is suitable for thinner aluminum materials. Hot bending is to heat the aluminum to a certain temperature and then bend it, which is suitable for thicker aluminum. The bent aluminum profiles have a beautiful and elegant appearance and are often used in building doors, windows, decoration and other fields.
4.Drilling processing
Drilling is one of the common operations in aluminum profile processing, mainly used to make connecting holes, mounting holes, etc. Common drilling methods include drilling with a drilling machine, drilling with a milling machine, etc. During the drilling process, it is necessary to pay attention to the accuracy of parameters such as hole diameter, hole depth, and hole spacing to ensure that the processed aluminum profiles can meet the usage requirements.
5. Tapping processing
Tapping is a method of processing internal threads on aluminum. Tapping requires a special tapping machine to process threads inside the aluminum material through cutting. Tapping processing is often used to make connectors, fasteners, etc., which has the characteristics of firm connection and easy disassembly. Commonly used in industrial profiles (T slot, V slot).
6. Milling processing
Milling is a method of processing aluminum profiles using a milling machine. Through milling, planes, grooves, bosses, etc. of various shapes and sizes can be processed. Milling has the advantages of high processing accuracy and good surface quality, and is often used to make complex structural parts of aluminum profiles.
Machining aluminium profiles offers several advantages: It allows us to save a lot of material since the profile has a geometry close to the final part(much better than starting with a solid bar). It enables fast and efficient production of serial parts thanks to high-speed machining. In addition, it provides dimensional precision, uniformity in the shape and finish of the part. This is a cost-effective process when large quantities of identical parts are produced, but it also has a reduced cost for smaller productions compared to other manufacturing processes provided, of course, that the minimum order for raw material is respected, which can be a limiting factor on occasion.