ALUMEC 2 Thi s i nf ormat i on i s based on our present st at e of know l edge and i s i nt ended t o provi de general not es on our product s and t hei r uses. It shoul d not t heref ore be const rued as a warrant y of speci f i c propert i es of t he product s descri bed or a warrant y f or f i t ness f or a part i cul ar purpose. ALUMEC 3 General ALUMEC i s a hi gh st rengt h al umi ni um al l oy suppl i ed i n t he f orm of hot rol l ed, heat t reat ed pl at e. It undergoes a speci al col d st ret chi ng opera- t i on f or maxi mum st ress rel i evi ng. Thanks t o i t s hi gh st rengt h and good st abi l i t y, ALUMEC has become w i del y used i n t he t ool i ng i ndust ry. Del i very condi t i on: heat t reat ed t o 146180 Bri nel l . Applicat ion areas The propert i es and charact eri st i cs w hi ch ALUMEC of f ers make i t an i deal mat eri al f or prot ot ype t ool s and f or moul di ng short and medi um l engt h produc- t i on runs w hi ch are not subj ect ed t o hi gh pressures or abrasi ve pl ast i cs. Consi derabl y short er t ool maki ng t i mes, l ow er t ool i ng cost s and short er cycl e t i mes gi ve val uabl e savi ngs bot h f or t he t ool maker and t he t ool user w hen usi ng ALUMEC. ALUMEC has t he f ol l ow i ng charact eri st i cs w hi ch make i t sui t abl e f or many t ypes of t ool s especi al l y pl ast i cs moul ds: Excellent M achinabilit y Hi gh cut t i ng speeds, reduced machi ni ng t i me, l ow er t ool i ng cost s, qui cker del i veri es. Low Weight The l ow w ei ght , w hi ch i s approxi mat el y 1/3 of t he w ei ght of st eel , al l ow s easi er and more conveni ent t ool handl i ng. Low i nert i a makes i t possi bl e t o speed up cl osi ng and openi ng of moul ds. High Thermal Conduct ivit y Cycl e t i mes are reduced and l ess compl i cat ed cool i ng syst ems may be used. Good St abilit y A speci al st ress rel i evi ng operat i on guarant ees mi ni mal def ormat i on duri ng and af t er machi n- i ng. Good Corrosion Resist ance Good resi st ance agai nst al l commonl y used pl ast i cs mat eri al s. Appl i cat i on Areas Prot o- Short Medi um Long t ypes runs runs runs Bl ow moul di ng X X X X Vacuum f ormi ng X X X X Foam moul di ng X X X (X) RIM-moul di ng X X X (X) Inj ect i on moul di ng of t hermopl ast i cs X X (X) Rubber moul di ng X X Hol ders and support pl at es, j i gs and f i xt ures Tool i ng Cat egory Suit able f or Surf ace Treat ment s ALUMEC can be hard anodi zed, hard chromi um or ni ckel pl at ed f or i ncreased hardness, w ear resi st ance and corrosi on resi st ance. ALUMEC 4 re 190 180 170 160 150 140 Vi ckers hardness 10kg VPN AA 7075-T651 HB 180 170 160 150 140 130 Cent er l i ne 150 mm ALUM EC Val ues at room t emperat ure unl ess st at ed ot herw i se. Densi t y kg/m 3 2 830 l bs/i n 3 0,102 Modul us of el ast i ci t y N/mm 2 71 500 psi 10,3 x 10 6 Coef f i ci ent of t hermal expansi on per C f rom 20C t o 100C 23 x 10 6 per F (68212F) 12,8 x 10 -6 Thermal conduct i vi t y W/m C 165 Bt u i n/f t 2 h F 1 144 Speci f i c heat J/kg C 890 Bt u/l b. F 0,20 TENSI LE STRENGTH Tensi l e st rengt h val ues, w hi ch f or most pract i cal purposes can be compared t o compressi on st rengt h val ues, shoul d be regarded as t ypi cal . Val ues at room t emperat ure f or di f f erent pl at e t hi cknesses. Pl at e (t hi ckness) Tensi l e st rengt h Yi el d st rengt h mm N/mm 2 N/mm 2 > 1050 590 550 > 50100 570 520 > 100150 550 500 > 150200 535 485 > 200300 430 365 Round bar (di amet er) mm 40 680 630 100 680 620 200 670 610 Not e t hat t he pl at e i s t est ed i n t he t ransverse di rect i on and t he round bar i n t he l engt h di rect i on. Propert ies PHYSI CAL DATA Hardness di st ri but i on t hrough t he pl at e cross sect i on CUTTI NG TOOL DESI GN AND M ATERI AL Al t hough al umi ni um al l oys gi ve l ow cut t i ng f orces, i t i s necessary t o use hi gh qual i t y cut t i ng t ool s. In order t o achi eve t he hi ghest possi bl e cut t i ng speed t he use of cement ed carbi de t ool s, especi al l y duri ng t urni ng and end mi l l i ng, i s i deal . The same cut t i ng t ool s normal l y used f or st eel can al so be used f or machi ni ng of ALUMEC. How ever, f or good product i on economy, t ool s w i t h l arge posi t i ve angl es shoul d be used. The f l ut e shoul d have a l arge chi p space and be pol i shed t o prevent chi ps cl oggi ng t he cut t er. When saw i ng ALUMEC, a coarse t oot h saw bl ade i s recommended. COOLI NG/ LUBRI CATI ON The purpose of cut t i ng f l ui d i s t o cool t he w ork pi ece and t o l ubri cat e t he cut t i ng t ool . Because of t he hi gh cut t i ng speeds possi bl e w hen machi ni ng ALUMEC, cool i ng i s i mport ant , al t hough t he heat conduct i vi t y of ALUMEC i s very hi gh. Good l ubri - cat i on i s of speci al i mport ance duri ng deep hol e dri l l i ng, as t here i s a prol onged cont act bet w een chi ps and t ool . Cut t i ng f l ui ds recommended f or st eel may some- t i mes di scol or t he al umi ni um surf ace, i f PH val ues are hi gh. Most manuf act urers of cut t i ng f l ui d have uni versal f l ui ds sui t abl e f or bot h st eel and al umi num. M achining GENERAL A maj or advant age w hen machi ni ng al umi ni um al l oys i s t he possi bi l i t y of usi ng hi gh cut t i ng speeds. The reason i s t he l ow cut t i ng f orce needed com- pared w i t h st eel and brass. Because of t he excel l ent combi nat i on of mechani cal and physi cal propert i es i n ALUMEC t he maxi mum cut t i ng speed possi bl e i s very hi gh, w hen sui t abl e cut t i ng t ool s are used. When usi ng hi gh speed mi l l i ng machi nes, cut t i ng speeds exceedi ng 3 500 m/mi n. (11 500 f t ./mi n.) has been used w i t h good resul t s. ALUMEC 5 Rough Fi ne Fi ne Turni ng t urni ng t urni ng t urni ng w i t h hi gh w i t h w i t h w i t h speed carbi de carbi de PCD 1) st eel Cut t i ng speed (v c ) m/mi n 6001200 12002500 6001500 250300 f.p.m. 19803960 39608250 19804950 825990 Feed (f ) mm/r 0,31,0 0,3 0,3 0,3 i .p.r. 0,0120,04 0,012 0,012 0,012 Dept h of cut (a p ) mm 26 2 3 3 i nch 0,080,24 0,08 0,12 0,12 Carbi de desi gnat i on ISO K20 K10 DRI LLI NG High speed st eel t wist drill 1) Indexabl e Sol i d Brazed i nsert carbi de carbi de 1) Dept h of cut (v c ) m/mi n 200400 200300 200300 f.p.m. 6651330 665990 665990 Feed (f ) mm/r 0,050,25 2) 0,100,25 2) 0,150,25 2) i .p.r. 0,0020,01 2) 0,0040,01 2) 0,0060,01 2) Carbide drill 1) Dri l l w i t h i nt ernal cool i ng channel s and brazed carbi de t i p. 2) Dependi ng on dri l l di amet er. Dri l l di amet er Cut t i ng speed (v c ) Feed (f ) mm i nch m/mi n f.p.m. mm/r i .p.r. 5 3/16 5070 165230 0,080,20 0,0030,008 510 3/163/8 5070 165230 0,200,30 0,0080,012 1015 3/85/8 5070 165230 0,300,35 0,0120,014 1520 5/83/4 5070 165230 0,350,40 0,0140,016 1) Poi nt angel 118 hel i x angl e 1630. Cut t ing dat a recommendat ions The cut t i ng dat a bel ow are t o be consi dered as gui di ng val ues w hi ch must be adapt ed t o exi st i ng l ocal condi t i ons. TURNI NG 1) Pol ycryst al l i n di amond. Rough Fi ne Fi ne Mi l l i ng mi l l i ng mi l l i ng mi l l i ng w i t h hi gh w i t h w i t h w i t h speed carbi de carbi de PCD 1) st eel Cut t i ng speed (v c ) m/mi n 6001000 10003000 8004000 250400 f.p.m. 19803300 33009900 265013200 8251320 Feed (f z ) mm/t oot h 0,20,6 0,10,2 0,050,2 0,4 i n/t oot h 0,0080,024 0,0040,008 0,0020,008 0,016 Dept h of cut (a p ) mm 28 2 2 8 i nch 0,080,32 0,08 0,08 0,32 Carbi de desi g- nat i on ISO K20 K10 M I LLI NG Face and square shoulder f ace milling 1) Pol ycryst al l i n di amond. End milling Sol i d Carbi de Hi gh carbi de i ndexabl e i nsert speed st eel Cut t i ng speed (v c ) m/mi n 300500 300500 120250 f.p.m. 9901650 9901650 400825 Feed (f z ) mm/t oot h 0,030,20 1) 0,080,20 1) 0,050,35 1) i nch/t oot h 0,0010,008 1) 0,0030,008 1) 0,0020,014 1) Carbi de desi gnat i on ISO K20 1) Dependi ng on t he radi al dept h of cut and cut t er di amet er. Mi l l i ng ALUMEC. ALUMEC 6 Elect rical Discharge M achining (EDM ) Machi ne set t i ngs are si mi l ar t o t hose used f or st eel but may need more pow er t o st abi l i ze. Met al re- moval rat es are 3 t o 4 t i mes t hat of st eel necessi - t at i ng good f l ushi ng t o avoi d arci ng. Copper el ect rodes gi ve best resul t s and show l ess w ear. Roughi ng el ect rodes are rarel y requi red. Phot o-et ching ALUMEC i s perf ect f or phot o-et chi ng t hanks t o i t s homogeneous st ruct ure. Surf ace t reat ment HARD ANODI SI NG ALUMEC can be hard anodi sed f or hi gher w ear resi st ance, gi vi ng a surf ace hardness equi val ent t o about 65 HRC i n st eel . Usual coat i ng t hi ckness i s 2050 m. Anodi si ng i s used t o a l i mi t ed degree i n moul d cavi t i es due t o t he di f f erence i n expansi on of t he surf ace l ayer rel at i ve t o t he underl yi ng al u- mi ni um. Thi s can l ead t o hai rl i ne cracki ng, spoi l i ng t he surf ace appearance of moul di ngs. Thi s surf ace i s usual l y accept abl e on non-moul di ng t ool part s, such as sl i des, w ear gui des, l eader pi ns and bushes, ej ect or pi ns, et c. Polishing guidelines GENERAL Mai nt ai n a cl ean w ork envi ronment and ensure t hat t he w ork pi ece i s f l ushed w i t h an appropri at e i ndust ri al sol vent t o prevent accumul at i on of pol i shi ng debri s. Use l arge t ool s w herever possi bl e t o prevent hi gh l evel s of l ocal i zed pressure l eadi ng t o surf ace degradat i on. Renew gri ndi ng paper f requent l y and change di rec- t i on of gri ndi ng bet w een grades. When w orki ng t owards a mi rror f i ni sh use copi ous quant i t i es of l ubri cant such as a l i ght oi l . See separat e l eaf l et Pol i shi ng of Tool St eel f or det ai l ed i nf ormat i on on pol i shi ng. TECHNI QUES Bot h mechani cal and manual t echni ques may be used. When seeki ng a mi rror f i ni sh t he use of pow er t ool s shoul d be avoi ded. ALUMEC i s i deal f or hi gh-st rengt h, l i ght wei ght di e-set s. GRI NDI NG A general gri ndi ng w heel recommendat i on i s gi ven bel ow. For gri ndi ng of ALUMEC use si l i con carbi de abrasi ve. Cut t i ng oi l i s recommended as gri ndi ng f l ui d. Type of gri ndi ng Wheel recommendat i on Face gri ndi ng st rai ght w heel C 46 H V Face gri ndi ng segment s C 24 G V Cyl i ndri cal gri ndi ng C 60 J V Int ernal gri ndi ng C 46 H V Prof i l e gri ndi ng C 100 L V M EDI A Carborundum paper shoul d be used f or gri ndi ng st art i ng w i t h grades 300 t hrough t o 800. When seeki ng a mi rror f i ni sh, cont i nue w i t h 1200 grade paper and i f necessary f ol l ow ed w i t h 6 mi cron/ 3 mi cron di amond past e. ALUMEC 7 Repair welding ALUMEC may be repai r w el ded usi ng ei t her Met al Inert Gas (MIG) or Tungst en Inert Gas (TIG) pro- cesses, t hough TIG i s not recommended f or l arge scal e repai rs. GENERAL GUI DELI NES Equi pment : 400 Amps rat i ng, Wi re Feed Mot or 7,510 m/mi n (2533 f.p.m.) (compared t o 3,7 m/mi n [ 12 f.p.m.] f or st eel ). Wel di ng w i re: AA5356 (Al 5% Mg), AA5556A (Al 5,2% Mg) or AA5087 (Al 4,5% MgMnZr). MIG 1,6 mm (0,063 i n.) di amet er. TIG 2,43,2 mm (0,0950,126 i n.). Furt her inf ormat ion Cont act your nearest Uddehol m represent at i ve f or more i nf ormat i on about al umi ni um and speci al st eel s f or t ool s. ALUMEC t ool The anodi si ng w i l l cause di mensi onal changes i n t he w orkpi ece, and al l owance shoul d, t heref ore, be made. Increase i n di mensi on i s about 50% of t he oxi de l ayer t hi ckness. The oxi de l ayer may be i mpregnat ed w i t h PTFE t o reduce adhesi on of t he pl ast i c. HARD CHROM E PLATI NG Hardness l evel s up t o and equi val ent t o 80 HRC are possi bl e usi ng processes w hi ch have been devel - oped f or al umi ni um al l oys. Pl at ed l ayer t hi ckness i s t ypi cal l y 0,10,2 mm (0,004" t o 0,008" ). CHEM I CAL NI CKEL PLATI NG Hardness l evel s equi val ent t o 50 HRC are possi bl e. Pl at ed l ayer t hi ckness i s t ypi cal l y 0,030,1 mm (0,001" 0,004" ) w hi l st adhesi on and corrosi on resi st ance are general l y superi or t o a chrome pl at ed f i ni sh. Pre-w el d preparat i on: Vert i cal f aces shoul d be machi ned t o an angl e and surf aces t o be w el ded, degreased. Oxi de l ayer must t hen be removed usi ng rot ary w i re brushi ng and w el di ng carri ed out w i t hi n ei ght hours. Pre-heat i ng: Pre-heat t o 50130C (120270F) t o of f set t he chi l l i ng ef f ect and hi gh t hermal conduc- t i vi t y of ALUMEC. Maxi mum met al t emperat ure duri ng w el di ng shoul d not exceed 200C (390F) i n order t o avoi d cracki ng af t er w el di ng.