In modern industry, the search for materials that offer lightness without sacrificing strength is constant. Aluminum, combined with numerical control technology, has established itself as a top-tier solution for demanding sectors such as aerospace, automotive, and electronics. But how is a block of this metal transformed into a high-precision component? CNC machining of aluminum is a subtractive process where machinery, guided by advanced software, removes material in a controlled manner to create parts with complex geometries and micrometric tolerances.

This article is a comprehensive guide to why aluminum is the preferred material for machining, the advantages this combination offers, and the key processes that enable the manufacture of everything from a structural component for an aircraft to a smartphone casing. Discover how CNC technology and aluminum can optimize your production and competitiveness.

Why is aluminum machined using CNC?

Aluminum is not a popular material by chance. Its intrinsic properties make it an ideal candidate for subtractive manufacturing processes, and CNC technology is the perfect tool to unlock its full potential.

The main reasons lie in its exceptional combination of physical and mechanical characteristics:

• Excellent strength-to-weight ratio : With a density almost three times lower than that of steel, aluminum allows for the manufacture of significantly lighter parts. Through alloying, mechanical strengths comparable to those of some steels can be achieved, which is critical in industries such as aerospace and automotive, where weight reduction is synonymous with efficiency.

• High machinability : This is defined as the ease with which a material can be cut. Aluminum is one of the metals with the best machinability, allowing the use of high cutting speeds and feed rates. This translates directly into a higher material removal rate, shorter production cycles, and consequently, a reduction in operating costs.

• Superior thermal conductivity : Aluminum dissipates heat very efficiently. During machining, this property helps to evacuate heat from the cutting zone, protecting the tool from premature wear and minimizing the risk of workpiece deformation.

• Corrosion resistance : Thanks to a natural process called passivation, aluminum develops a thin oxide layer on its surface that protects it from oxidation and other chemical agents. This ensures greater durability of the parts, even without additional surface treatments.

Vurcon's expert tips for machining aluminum

To position ourselves as your technical partner, we share some practical tips to maximize your results:

• For optimal surface finish , use 2- or 3-flute end mills with a TiCN (titanium carbon nitride) coating. This type of tool facilitates excellent chip evacuation, which is key to preventing clogging.

• Ensure a constant and abundant flow of coolant . This not only lubricates and cools the cutting zone, but also helps to expel chips from the cavities, preventing them from sticking to the tool or workpiece.

• Don't underestimate clamping . Although aluminum is a soft material, high machining speeds generate considerable forces. Use reliable clamping systems to prevent vibrations that can affect the accuracy and finish of the part.

Advantages of CNC machining in aluminum

When the properties of aluminum are combined with the precision of numerical control, the result is a manufacturing process with direct benefits for any workshop. CNC technology not only automates production but also elevates quality and design possibilities to a new level.

The most notable advantages are:

• High precision and repeatability : The CNC executes the instructions of a digital program with extraordinary accuracy, achieving tolerances as low as ±0.01 mm. More importantly, it can replicate this precision across thousands of identical parts, ensuring consistent quality and eliminating human operator variability.

• Manufacturing complex geometries : Software control allows for the creation of designs with geometric complexity that would be impossible or prohibitively expensive to achieve using manual methods. From curved surfaces to internal cavities, CNC opens the door to innovation in the design of lighter and stronger components.

• Improved efficiency and productivity : CNC machines are designed for continuous operation with minimal human intervention, maximizing uptime. The ability of Vurcon machining centers , such as those in the VL series, to perform multiple operations in a single setup dramatically reduces cycle times.

Vurcon performance data : To give you an idea of ​​real-world performance, our vertical machining centers achieve spindle speeds of up to 10,000 RPM. This allows for material removal rates on alloys like 6061 aluminum that are 70% higher than those of conventional equipment from a decade ago, transforming the productivity of your workshop.

Simplified success story: A customer in the mold industry reduced the machining time for an aluminum plate from 45 minutes to just 18 minutes after installing a Vurcon VL-85 machining center. This allowed them to accept 30% more orders per month, recouping the investment in less than 22 months.

Cost optimization for short runs and prototypes : Unlike other methods that require expensive molds, CNC machining of aluminum is highly flexible. It allows for cost-effective production of anything from a single prototype to medium-sized production runs.

Types of parts that are machined from aluminum

The versatility of CNC-machined aluminum has made it a cornerstone for the most innovative and demanding industries. Its ability to produce lightweight, strong, and precise components is applicable to countless products.

Some of the most relevant sectors and applications include:

• Aerospace sector : This is the prime field for high-strength aluminum. CNC machining is used to manufacture critical structural components such as wing ribs, bulkheads, and engine mounts, where weight reduction is crucial.

• Automotive industry : To improve efficiency, manufacturers use aluminum in engine components, chassis parts, and suspension. High thermal conductivity is vital for heat dissipation, and its light weight improves vehicle dynamics.

• Consumer electronics : The casings of products such as laptops and smartphones are machined from a single block of aluminum ("unibody"). This process provides a premium aesthetic and robustness, ensuring the perfect assembly of the internal components.

• Medical sector : The medical industry relies on CNC machining to manufacture everything from surgical instruments and orthopedic devices to implants. The ability to produce complex shapes with smooth finishes is essential for patient safety.

Most common processes in CNC machining of aluminum

To shape aluminum, CNC machinery employs various subtractive operations. Each is designed to achieve specific geometries, and they are often combined in a single part. The fundamental processes are:

1. CNC Milling : A rotating tool (milling cutter) removes material from a stationary workpiece. It is the ideal process for creating flat surfaces, cavities, and complex contours. Vertical machining centers , such as those in our Vurcon VL series , are the machines par excellence for milling.

2. CNC turning : The workpiece rotates at high speed while a cutting tool moves to shape it. It is ideal for creating components with axial symmetry, such as shafts and pins. CNC lathes , like those in our Vurcon PL series , are the specific solution for these applications.

3. CNC Drilling : This is used to create holes in a workpiece using a rotating drill bit. CNC also allows for secondary high-precision operations such as reaming (to improve the finish) and tapping (to create internal threads).

Vurcon's commitment: beyond the machine

At Vurcon, we understand that a machine is a long-term strategic investment. That's why our commitment goes beyond the sale. All our equipment includes local technical support, initial operator training , and a guarantee of critical spare parts availability in less than 48 hours . Our goal is clear: to ensure your production never stops and that your investment is profitable from day one.

Ready to take your aluminum production to the next level? Contact our team of specialists for personalized advice and discover how our CNC solutions can optimize your workshop.