Dry Machining Aluminium

Research and Development into Dry Machining Aluminium

Cutting Costs and Boosting Performance for Precision Parts: Universal Fabrications

As leading aluminium machining specialists in the West Midlands, we help customers get their parts machined efficiently and sustainably. At Universal Fabrications, innovation is at the heart of everything we do to serve our customers better. From November 2024, through a six-month R&D initiative, our team pioneered advancements in precision machining for lightweight aluminium components. By reimagining processes for alloys such as 6082-T6 and 7075, we aimed to reduce costs, boost reliability, and align with sustainability goals.

The Challenge: Overcoming Coolant Drawbacks

Conventional aluminium machining for structural parts often uses flood or minimum quantity lubrication (MQL) for cooling and smooth finishes. Yet, we pinpointed key issues affecting our customers:

  • Extended Production Delays: Coolant infiltration into internal cavities demanded up to six hours of manual cleaning per unit, hindering timely deliveries.
  • Compromised Reliability: Lingering coolant residues undermined sealing effectiveness, risking rework and operational failures.
  • Environmental Concerns: Coolant-generated chemical waste clashed with customers’ eco-friendly priorities. Our mission was to eradicate these hurdles and unlock superior value.

Our Breakthrough: Advanced Dry Machining

We engineered a coolant-free machining approach that upholds the precision, durability, and quality our customers demand. During the six-month trial, our engineers meticulously evaluated dry machining methods, fine-tuning cutting parameters, tool coatings, and feed/speed rates for 6082-T6 and 7075 alloys.

Universal Fabrications dry machining aluminium part in west midlands

The outcomes provided substantial advantages

  • Greater Quality: Surface finishes and dimensional precision consistently matched or surpassed tolerances across various geometries.
  • Durable Tooling: Enhanced coatings delivered reliable tool longevity, curbing downtime and expenses.
  • Accelerated Turnaround: Without coolant, cleaning times plummeted, sealing improved, and components shipped faster.

Quantifiable Results: Transforming Customer Success 

This dry machining advancement yielded tangible benefits: 

  • Exceptional Component Integrity: Consistent surface quality and stability met tolerances for diverse designs, guaranteeing dependable performance.
  • Reliable Tool Efficiency: Optimised settings and coatings kept tool life viable, enabling economical operations. 
  • Productivity Boosts: Ditching coolant slashed cleaning efforts, elevated sealing rates, cut labour costs and material costs, and heightened reliability.

The Bigger Picture: Prioritising Customer Needs

We crafted this innovation to directly tackle customer priorities:

  • Cost Savings: Less cleaning and reduced rework translated to lower expenses and sharper pricing.
  • Greater Dependability: Greater sealing upheld peak performance in demanding uses.
  • Eco-Conscious Practices: Zero coolant meant reduced chemical waste, advancing sustainability targets.

This milestone has optimised workflows for our customers and fuels ongoing R&D for even greener, more efficient innovations.

Services Overview: Our Comprehensive Aluminium Machining Capabilities 

  • CNC Milling: 3, 4, and 5-axis milling for complex geometries in aluminium and other materials.
  • Turning: Turn/mill lathes and sliding head lathes for precise cylindrical components.
  • Welding: MIG, TIG, laser, spot, and projection welding, including robotic welding for structural elements.
  • Prototyping: From design to rapid prototype development, assembly, and inspection.

Our dry machining innovation integrates seamlessly into these services, particularly for precision machining of aluminium alloys like 6082-T6 and 7075. This allows us to handle everything from intricate turned and milled parts to large-scale fabricated and machined assemblies up to 2m x 2m, delivering turnkey solutions with enhanced efficiency and sustainability.

FAQs: Common Questions About Our Aluminium Machining Services

What makes Universal Fabrications the best choice for milling aluminium in the Midlands?

With over 45 years of experience in precision engineering, Universal Fabrications stands out as a top aluminium machining specialist in the West Midlands. Our ISO 9001 certification ensures the highest quality standards, while our commitment to sustainability, through innovations like dry machining, helps customers meet eco-friendly goals without compromising performance.

How can dry machining benefit my aluminium parts project?

Dry machining eliminates coolant-related issues, reducing costs, improving sealing reliability, and supporting faster production timelines, all while aligning with sustainable practices.

What types of aluminium alloys do you specialise in?

We excel in machining alloys like 6082-T6 and 7075, optimising processes for lightweight structural components across industries such as aerospace, automotive, and EV manufacturing.

Your Trusted Partner in Precision Aluminium Machining?

Universal Fabrications is the go-to partner for high-precision aluminium work, offering quality, affordability, and sustainability across applications. Whether crafting detailed turned and milled pieces or expansive 2m x 2m fabricated assemblies, our dry machining expertise highlights our dedication to solving your most complex challenges. Eager to see how this can transform your project? Reach out to our team today for customised strategies that propel your success.

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