Workpiece deformation is one of the most common challenges in aluminum alloy machining. The causes are closely related to machining technology, raw material properties, part geometry, and production conditions. Internal stress within the blank, cutting force, cutting heat, and improper clamping force can all directly lead to deformation during processing.
As a professional carbide end mill manufacturer supplying CNC milling tools and universal carbide cutters, we often help customers optimize their machining workflow to reduce deformation and improve overall productivity. Below are several proven strategies to effectively minimize deformation during aluminum machining:
1. Reduce Internal Stress in the Raw Material
Lowering the internal stress of the aluminum blank is one of the most effective ways to prevent deformation. Natural aging, artificial aging, and vibration stress relief can all partially release built-in stress.
Pre-machining is also a highly practical technique. Large, bulky blanks typically contain significant excess stock, which leads to larger deformation after machining. By removing excess material in advance and reducing the machining allowance in each area, you can not only decrease deformation in subsequent processes but also allow the blank to release part of its internal stress when left to rest after pre-machining.
2. Improve Cutting Tool Performance
The cutting force and cutting heat generated during machining play a major role in deformation. This makes choosing the right tool essential. Tool materials, tool geometry, and cutting-edge design all directly influence the cutting load applied to the part.
Selecting high-performance carbide tools—such as universal carbide cutters and precision CNC milling tools—helps reduce heat generation and vibration while maintaining consistent material removal. Optimizing rake angles, clearance angles, and tool edge strength further contributes to lower deformation and improved dimensional accuracy.
3. Plan Machining Processes Reasonably
In high-speed machining, large allowances and intermittent cutting often introduce vibration, affecting dimensional accuracy and surface finish. Therefore, CNC machining of aluminum alloy parts is generally divided into several stages:
Roughing → Semi-finishing → Corner cleaning → Finishing
For components with tight tolerances, a second semi-finishing step may be required before final finishing. After roughing, allowing the part to cool naturally can help release the stress generated during the first operation, thus reducing deformation.
For rough machining, the remaining allowance should be greater than the expected deformation—typically 1–2 mm. During finishing, keeping a uniform allowance of 0.2–0.5 mm ensures stable tool engagement and reduces cutting deformation, resulting in better surface quality and higher precision.
