Zinc Machining: Types and Tips
Zinc is one of the most commonly used materials, and different industries use zinc-based components in their applications. Zinc material can be converted into components of different shapes and sizes through machining.
If you want to learn about zinc machining, its properties, types, and applications, the guide below has it all.
Properties and Characteristics of Zinc
The main reason for using zinc in different applications is the characteristics it possesses, and some of these are as follows:
- Zinc has a high tensile strength and offers durability when chosen for structural applications.
- It is highly corrosion resistant and is suitable for use in harsh conditions without corroding.
- Zinc offers ductility and hence can be shaped in different designs without breaking.
- Zinc is affordable and always available, which makes it a cost-effective choice.
Benefits of CNC Machining Zinc
CNC machining zinc comes with various benefits, some of these are as follows:
- CNC machining is a process that offers high precision and hence can manufacture components with tight tolerance. Therefore, zinc components can easily be machined to create complex shapes accurately.
- Zinc machining is an efficient process, and along with the affordability of the material, the process is also cost-effective. It ensures high quality at a low expense.
- Zinc is versatile and can easily have alloys created with copper and aluminum. These alloys can be machined to improve the mechanical properties of components.
- Zinc is durable, and when subjected to machining, it can create long-lasting parts.
- Due to the corrosion resistance offered by zinc, the components manufactured are also suitable for use in harsh conditions.
Types of Zinc Alloys for Machining
Zinc alloys of different types are used when it comes to zinc machining, and some of these are as follows:
Zamak 3
Zamak 3 has 96% zinc and 4% aluminum, with some traces of iron, copper, and magnesium. It offers high dimensional stability, strength, and ductility and is highly castable. It even offers excellent electrical conductivity and high corrosion resistance.
Zamak 5
Zamak 5 has 4% aluminum, 1% copper, and 95% zinc in its composition. Copper enhances the strength of zinc alloy, and compared to other grades, it is less ductile. However, it is highly suitable for machining.
ZA 8
ZA 8 has 8.4% aluminum with the rest of the zinc and is known for its high creep strength and hardness. It is compatible with multiple surface finishing processes and is opted for decorative purposes.
It is compatible with most of the die-casting processes and has high fluidity, which helps manufacturing components with complex shapes and detailed features.
EZAC
EZAC is a unique zinc alloy that is composed of copper and aluminum. It is among the best zinc alloys and has excellent hardness, strength, and creep resistance.
It is used mostly in die-casting applications as it has improved fluidity and melting point.
ZA 27
ZA 27 is a zinc alloy that has a high aluminum content of around 28% with 2.5% copper. It is hard, lightweight, and strong and has excellent creep resistance. It offers a high melting point and is suitable for cold chamber die casting.
Tombak
Tombak is a brass alloy which has zinc in the range of 5 to 20%. It is a malleable material which is affordable and has a shiny appearance.
It can also take different colors based on the composition of the alloyed elements like lead, copper, and tin. It is mostly opted for manufacturing medals, buttons, and decorative items.
Different Machining Processes for Zinc Alloy
Zinc machining can be carried out using different processes, and these are as follows:
Fraisage
Fraisage is used to manufacture zinc components that have irregular shapes. The milling process is done through 5-axis CNC machining so that components with complex shapes can be manufactured.
Turning
Turning helps manufacture zinc components, which are shaped like a cylinder. It uses lathe machines and creates components that are highly accurate.
Forage
Le process of drilling is used to create holes in the zinc components. It uses different drill bits and creates holes in different diameters.
EDM
EDM is a process that allows the manufacturing of zinc components that have prismatic shapes. Since zinc alloys have good electrical conductivity, they are highly compatible with EDM.
Moulage sous pression
Die casting is an efficient process of manufacturing and producing zinc components with tight tolerance and precise shapes. The process uses dies and molds to create the required components.
Surface Finish Options for Zinc Parts
Zinc components can be subjected to different surface finishing options, and these are as follows:
Electroplating: Zinc parts are electroplated with materials composed of cobalt and nickel. It enhances the corrosion resistance of the parts and improves the surface finish.
Chromate Conversion Coating: It is applied on zinc alloys so that different colors and an aesthetic look can be achieved.
Powder Coating: The process of powder coating gives a rough look to the components and makes them resistant to scratching and chipping.
Anodizing: The anodizing process creates a thin layer of oxide on the surface of zinc components to enhance its corrosion resistance.
Painting: Zinc alloys can be painted to have any color required by application.
Applications of Zinc Parts
Zinc components are opted for multiple applications, and some of these are as follows:
Automobile
The automobile industry uses zinc for manufacturing components like brakes and parts of engine blocks.
Électronique
Zinc has excellent thermal and electrical conductivity. It is, therefore, used to make electronic enclosures and dissipateurs thermiques.
Médical
Zinc offers biocompatibility and hence can be used to manufacture medical instruments that will be safe to use within the human body.
Hardware
Zinc alloys are widely used in hardware like nuts, screws, and fasteners. They have excellent strength and are suitable for fitting-related applications due to their corrosion resistance.
Practical Tips for Machining Zinc Alloy
When machining zinc alloy, some of the essential tips to consider for desired results are as follows:
- There are differing zinc alloys. When it comes to choosing the ones for machining, they choose those that are easy to machine, like Zamak 3 and Zamak 5.
- Zinc alloys possess gumminess, and to handle it and minimize tool wear, sharp cutting tools are needed.
- The application of coolant during zinc machining should be generous so that thermal softening can be avoided. It helps produce an enhanced surface finish and even controls chip production.
- Zinc alloys heat up quickly, and hence, the cutting speed must be kept high to reduce the temperature.
- It is suggested to opt for either high-speed steel tools or carbide tools to deal with the wear of the tool while machining zinc alloys.
Start Your Custom Zinc Parts Project with DEK
Zinc machining is a process that offers high-accuracy components. If you are also in search of components made using zinc alloy, get in touch with us at DEK.
We have been offering zinc machining services to multiple industries for years. We have an expert team and highly advanced equipment that offers seamless components.
Conclusion
Zinc machining allows it to cater to many industries, and there are different types of alloys of zinc, each having suitability for different applications.
As you have read the guide above, you must have learned everything about zinc machining, and it will help you with your zinc machining project.
