CNC Machining Alloy Steel: All You Should Know
CNC machining is a process that uses machine tools and removes the material layers from the workpiece helping to produce custom components. Alloy steel CNC machining is opted for manufacturing alloy steel components. If you are willing to explore the fundamentals of alloy steel CNC machining, the benefits of using alloy steel, and its applications, you can go through this guide below.
What is Alloy Steel?
Alloy steel is a steel that has a composition of other elements like manganese, vanadium, molybdenum, nickel, and chromium. These elements are added to the steel to improve its mechanical properties. These additions lead to making the steel resistant to wear and corrosion and also add strength to it.
The alloy steel is a versatile material that is commonly used in many types of applications due to its excellent performance.
CNC Machining Alloy Steel Process
CNC machining alloy steel consists of using precise tools of machining which offers the workpiece to appear in the desired form. The two primary methods of CNC machining used for alloy steel components are CNC milling and CNC turning and are discussed below:
Fresado CNC
Fresado CNC is a process of machining that uses rotary cutters helping to remove the material from the workpiece and allowing to create components with detailed features and complex layouts. The process of CNC milling requires keeping the workpiece fixed on the machining table and the tools rotate. The tools used in CNC milling are made either using high-speed steel or carbide based on the toughness of the material.
As the spindle of the tool rotates the desired shape is carved out on the workpiece. During the process, coolants are used to manage heat and ensure a refined surface of the component with tight tolerance is achieved.
Torneado CNC
Torneado CNC involves the process in which the cutting tool remains stationary and the workpiece rotates helping to eliminate material from the alloy steel to shape it. CNC turning is a process suitable for cylindrical parts. The workpiece is clamped and the carbide-made cutting tools help achieve the required finish.
During the machining process, coolants are used for heat control and maintaining the tool's sharpness.
Types of Alloy Steel
Alloy steel has various categories in which alloying elements are added in varied proportions and some of the common types of alloy steel are as follows:
Low Alloy Steel
Low alloy steel comprises a very small percentage of alloying elements which is usually less than 5%. These steels are known for their hardness, enhanced mechanical properties, and toughness. These steels are used in applications like pipelines, automobiles, and construction machinery. Some of the common types of alloy steel are alloy steel 4130, alloy steel 4140, and acero aleado 4340.
High Alloy Steel
High alloy steel comprises a high alloying element percentage which is more than 5%. These steels have characteristics like high corrosion resistance, high wear resistance, and high performance under extreme temperatures. High alloy steel consists of 304 and 316 stainless steel and this type of steel is used in aerospace components, chemical processing, and medical industry.
Maraging Steel
Maraging steel is a very special type of steel that has a low content of carbon. It offers ultra-high strength and has great ductility. It is hardened with the help of intermetallic compounds which are precipitated. Maraging steel is commonly used in weapons, the manufacture of tools, and aerospace components.
Acero para herramientas
Tool steel is a type of alloy steel which is mostly opted for manufacturing tools. The tool steel is known for its hardness, toughness, and resistance against wear, it even resists softening when subjected to high temperatures.
Benefits of Alloy Steel CNC Machining
CNC machining of alloy steel has various advantages and hence the process of CNC machining is therefore used in manufacturing alloy steel parts. Some of the benefits offered by machining alloy steel are as follows:
Improved Durability and Strength
Alloy steel is known for its mechanical properties and hardness, it is therefore considered to be suitable for the components that require high stress and wear resistance. The CNC machining ensures that the properties of alloy steel are retained by the components and the parts have strength and durability.
Alta precisión y exactitud
CNC machining comprises high precision and accuracy which is very important for manufacturing intricate designs and complex shapes. Precision is also very important in applications where alloy steel components with tight tolerance are needed.
Consistent Components
The process of CNC machining is automated and it offers consistent production. The CNC program is set up once, and the parts can be produced repeatedly in large volumes. It helps minimize the errors and also ensures uniformity across the large volume of components offering savings in cost as well as time.
Versatile Process
Mecanizado CNC is a versatile process that comprises milling and turning which helps produce a wide range of alloy steel parts. The manufacturer can therefore use different processes and manufacture parts that are highly complex and require diverse shapes and detailing.
Limitations for Custom Alloy Steel Parts
CNC machining of alloy steel has various benefits but there are some limitations as well which include:
Coste elevado
The alloy steel is highly expensive compared to other materials like carbon because the cost of the alloying elements is high. The high cost is usually a limitation in projects that have limited budgets for producing alloy steel components.
Challenges in Machining
The alloy steel is tougher compared to other materials which makes it challenging to machine easily. Hence, the toughness of the alloy steel leads to high tool wear and it ends up requiring frequent tool changes.
Limitation in Layout
The process of CNC machining is quite versatile but still, there are certain size and shape limitations for the parts manufactured using alloy steel. The parts that are large in size may be a bit challenging to the machine through the CNC machining processes.
Time-Consuming
The process of prototyping, designing, and producing custom alloy steel components is a time-consuming process. The alloy steel components after CNC machining may also need some post-processes which also leads to an increase in the time to manufacture components.
Material Waste
The CNC machining process is no doubt a highly precise method for manufacturing components, but it also causes a lot of material waste due to being a subtractive manufacturing technique. Steel alloy is an expensive form of material and hence the wastage could add up to the component cost as well.
Tips to Alloy Steel CNC Machining
Some of the tips when CNC machining alloy steel may prove to be very significant during the machining process and these are as follows:
- The selection of appropriate tools for CNC machining alloy steel is very important, these tools may comprise high-speed steels and carbide. The hardness of the alloy steel must be machined with a similar tough tool so that it helps to enhance the performance of the tool and also reduces the need for maintenance of the machining tools.
- Choose the correct parameters for cutting during the process of machining. Adjust the feed rate, cut depth, and cutting speed based on the type of steel alloy you have chosen.
- The application of coolants and lubricants helps in heat dissipation and it also reduces the friction caused during the process of machining. It even helps to prevent the wear and tear of tools and deformation of the components.
- The workpiece should be properly clamped and must be stable and rigid to achieve the required accuracy and surface finish in the component.
- Always monitor the wear and tear of tools so that you can always achieve the right machining quality, and this way timely replacement of the tools can also be carried out.
Post-Processing and Surface Finishes Options On Alloy Steel Parts
The alloy steel parts may need post-processing and surface finishing after manufacturing and some of these processes are given below:
Tratamiento térmico
Tratamiento térmico helps to alter the properties of alloy steel with the help of processes like annealing, tempering, and quenching. The process of annealing helps to improve machinability and quenching, and tempering increases the toughness and hardness of the component. The automobile parts and tools may require heat treatment as alloy steel parts.
Chapado y revestimiento
The process of coating consists of recubrimiento en polvo which helps add a layer of protection over the alloy steel components. In the process of plating the layer of protection is deposited using electric current on the alloy steel component. It helps in adding corrosion resistance to the alloy steel components and also enhances its aesthetics. The outdoor equipment and construction materials made using alloy steel are post-processed with plating or coating.
Chorro de arena
Chorro de arena helps to remove scale and rust from the surface of the alloy steel components. In the process of sandblasting tiny particles are blasted on the surface of the component with pressure. The process of sandblasting is undertaken before painting the alloy steel parts.
Anodizado
El proceso de anodizado helps apply a thick layer of oxide on the surface of the alloy steels. It is commonly used for the purpose of offering protection to alloy steel components used in aerospace, automobile, and architectural applications that need corrosion resistance.
Applications of Alloy Steel CNC Machining
Machined alloy steel components are used in various industries like aerospace, medical, industrial machinery, and automobile sectors. Some of the components manufactured using CNC machining alloy steel are as follows:
- Engine blocks
- Turbine blades
- Ejes
- Engranajes
- Implantes médicos
- Valves and fittings
The CNC machined alloy steel components are known for their exceptional performance, durability, corrosion resistance, and precision which enhances the functionality and lifespan of the alloy steel component.
Conclusión
Learning about alloy steel machining must have given you a detailed understanding of what alloy steel is and how it can be useful in different applications after CNC machining. If you are looking for CNC-machined alloy steel custom components, you can get in touch with DEK and discuss your specifications with us. We can provide you with accurate, versatile, and highly precise alloy steel components.
Preguntas frecuentes
Is alloy steel easy to machine?
Yes, alloy steel is hard and tough which makes it difficult to machine and it requires the right tools and machining parameters to achieve the desired component out of it.
What’s the Difference Between Steel and Iron?
Iron is an element that occurs naturally and steel is an alloy that is made by adding carbon and some other elements in iron to enhance its durability and other properties.
