6. Cutting methods for aluminum materials: Suitable cutting machines and cutting conditions.
The machinability of aluminum varies greatly depending on its alloy composition and manufacturing method. We will introduce suitable saw blades and cutting conditions for each representative aluminum material.
▶️ Aluminum sash and extruded materials (such as A6063) - Characteristics: Thin-walled, hollow cross-section / Relatively soft extruded material - Recommended tool: Alternating incline triple chip blade (negative angle / 80-120 teeth) - Feed speed (fz): 0.02-0.10 mm/tooth - Point: To prevent blade biting, a front angle of neutral to negative is recommended. Light application of lubricant is effective in preventing welding. ▶️ Aluminum sheet materials (such as A5052, A6061) - Characteristics: Thickness of 10mm or more, high strength, prone to work hardening - Recommended tool: Triple chip blade (50-80 teeth) with a robust design featuring relief angles - Feed speed (fz): 0.04-0.07 mm/tooth - Point: Excessive high-speed rotation poses a risk of heat generation. To avoid blade binding during cutting, blades with a split tooth structure are effective. ▶️ Fin-equipped heat sinks (extruded materials) - Characteristics: Fine fin sections + medium-thick base - Recommended tool: Triple chip blade (negative angle / 90-120 teeth) - Feed speed (fz): 0.03-0.06 mm/tooth - Point: Focus on burr suppression. Use a sharp new blade and apply a small amount of lubricant. Due to the thin material, a tooth count setting that ensures 2-3 teeth are always in contact is necessary.
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▶️ Aluminum castings and die castings (ADC12, Si series) ✅ Characteristics: High silicon content, hard and brittle / Strong wear resistance ✅ Recommended tools: Coarse pitch (30-60 teeth) + PCD or coated blades ✅ Cutting speed: 15-40 m/s ✅ Feed rate (fz): 0.03-0.05 mm/blade ✅ Points: Basic requirement is a wear-resistant cutting edge and low-speed cutting. It is essential to use a dust collector to effectively discharge powder-like chips. ▶️ Comparison table of cutting conditions | Material | Blade Type | Example Teeth | Cutting Speed (m/s) | fz (mm/blade) | |--------------------|--------------------------|---------------|---------------------|----------------| | Frame materials | Alternating incline/Negative | 80-120 teeth | 50-80 | 0.06-0.10 | | Sheet materials (10mm+) | Triple / With relief angle | 50-80 teeth | 40-60 | 0.04-0.07 | | Heat sinks | Triple / Fine teeth | 90-120 teeth | 60-80 | 0.03-0.06 | | Castings | Coarse pitch PCD blade | 30-60 teeth | 15-40 | 0.03-0.05 |
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▶️ Compatibility of Okumura Machinery Manufacturing's Models | Model | Compatible Materials | Features (Reference Models) | |----------------------|---------------------|--------------------------------------| | UCA Series | Sashes, Shaped Materials | Undercut Method + Integrated Dust Collection System (UCA-300DC) | | ACA Series | Sashes, Shaped Materials | Overcut Method + Angle Cutting (ACG2) | | JCU Series | Sashes, Shaped Materials | Upcut Method + Angle Cutting (JCU-510D) | | UCA-T Series | Aluminum Plates, Copper Bars | Undercut Method + Copper Bar Cutting (UCA-T 250R) | | URK Series | Thick Aluminum Plates | Split Blade Structure + Compatible with Large Diameter Blade t200mm (URKG2000) | | UCACHM Series | General Shaped Materials | Automatic Fixed-Length Feeding + High-Speed Mass Production Compatible (UCACHM400-62) | ▶️ Summary Optimizing blade types, peripheral speeds, and feeding speeds according to aluminum materials directly leads to high-quality cutting and extended tool life. It is crucial to identify the characteristics of the processing materials and fine-tune the condition settings. Support for selecting cutting conditions by specialized staff is also available! Please feel free to consult "OKUMURA SELECT."
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Okumura Machinery Manufacturing Co., Ltd. was founded in Takamatsu City in 1952. We began manufacturing woodworking machines in 1965 and consistently focused on aluminum profile cutting in the 1970s, achieving success in this area. By focusing on the goal of ensuring and improving our customers' productivity, we became a market leader in aluminum cutting machine manufacturing. With a product range of over 100 items, we can meet various customer needs. Additionally, our semi-custom machine designs allow us to provide products tailored to various fields and company sizes. Our domestic product range, which exceeds 6,000 units, speaks to our capabilities. However, what we take particular pride in is that we have remained a grounded company that embodies the values of small and medium-sized enterprises, such as quality, flexibility, individuality, reliability, and closeness to our customers. One indicator of the superior quality of our products is their longevity, with many of our products being used for over 30 years. Our goal is to develop perfect products for our customers. We look forward to being your partner in providing products and services that understand and meet your needs at Okumura Machinery Manufacturing Co., Ltd.
