Aluminum machining live: How feed rate changes the surface – with in-process measurement
“Aluminum is easy.” – Really?
Maybe on paper. In practice, it often looks very different:
🔴 Tool wear that strikes faster than expected
🔴 Surfaces that do not become uniform
🔴 Greasy chips that stick to the tool
And all this despite the fact that the components are supposedly known. The cause rarely lies in the material alone, but almost always in the interaction of the entire process system.
In our workshop „Zerspanung ALU“, we took a close look at precisely this interaction: What makes aluminum so special as a material? What role does the synchronization of all process partners play? And what does a stable aluminum process look like that also works in practice?
The practical part was followed by direct implementation: two defined surfaces were produced using a PCD milling head with different feed rates – one with an Rz of 8 and one with an Rz of 13. We mastered demanding challenges such as thin-walled webs, ramps with different angles in the full groove with simultaneous axial and radial loads on the tool and low-burr holes.
Aluminum machining for e-mobility: LiCON LiFLEX I 17136 & HAM diamond milling cutter in action
What happens when two companies from Upper Swabia combine their strengths?
The result is more than just a project – it’s a vision realized through high-precision CNC machining, innovative manufacturing technology and a strong partnership.
We were able to contribute our expertise to a challenging project from LiCON: A battery frame made of the aluminum alloy AlSiMg for the e-mobility sector with dimensions of 1600 x 1300 x 115 mm was precisely machined on the high-performance LiFLEX I 17136 GigaLine machining center using our special diamond milling cutter system.
The result? The highest machining quality, maximum efficiency and absolute precision, supported by genuine trust and bundled expertise.
🤝 Thanks to the entire LiCON team for the strong collaboration and trust, true to the motto: “Global solutions from Upper Swabia into the world.”
Live steel machining in the workshop “The HAMamzing Smart Factory” | Digital Process Chain Live
🚦 Downtime or progress? Tomorrow’s production needs more than just precision. It needs intelligent processes that optimize themselves.
But the reality is often different:
🔴 Manual data input that provokes errors
🔴 Tool search times that waste valuable production time
🔴 Unnecessary downtime because processes are not optimally linked
Why are many companies still struggling with these problems, even though the solution already exists?
💡 The digital process chain is the key! Instead of using isolated individual solutions, we intelligently link all manufacturing processes – from initial planning to final machining. The result? Fewer errors, more efficiency, maximum productivity.
But what does this look like in practice? This is exactly what we demonstrated live at our showroom during our last workshop on the digital process chain. From tool planning and simulation to finished machining, participants were able to experience what modern production looks like today. Not just theory, but real solutions in action!
Live titanium machining in the workshop ‘Hart – Härter – HAMmer”
With their impressive hardness and dimensional stability, hardened materials stand for precision and durability. But machining them is a real challenge. In our last we combined both theory and practice and demonstrated live how hard machining can be achieved effortlessly.
*** The initial situation ***
🚩 Machining of a connecting rod mold through-hardened to 62 HRC (X155CrVMo12-1)
*** The challenge of hard machining (among other) ***
❌ Tool wear: Hard materials put a lot of strain on tools
❌ Heat generation: Insufficient cooling leads to high temperatures
❌ Machining parameters: Incorrect parameters affect precision and tool life
*** Our HAMazing solutions ***
✅ Selective carbide selection for optimum material properties
✅ Perfect adaptation of the tool geometry to the specific requirements
✅ Hyper smooth polished tool surfaces and reproducible main and secondary cutting edge preparation thanks to our unique Hybrid Surface Finish polishing process
✅ Optimal coatings for wear resistance, temperature resistance and friction reduction
Live titanium machining in the workshop ‘The Swabian Titan
With its outstanding strength and durability, titanium has become an indispensable part of modern manufacturing, even if its machining remains challenging. During our workshop last week, we demonstrated live how our new HAM titanium range and advanced cooling methods efficiently overcome this challenge. This is what future-oriented production looks like:
*** The initial situation ***
🚩 Machining of an aerospace part (150 x 110 x 50 mm) in grade 5 titanium (Ti6Al4V; 3.7164) completely with minimum quantity lubrication (MQL) only
*** The challenge of machining titanium ***
❌ Increased wear due to high cutting forces and temperatures
❌ Tool wear due to diffusion
❌ Due to the low thermal conductivity, the temperature is conducted into the tool
*** Our HAMazing solution ***
✅ 40-3011: Our 5-cutter for trochoidal milling
✅ 40-3001: Our 3-cutter for full-slot milling up to 1.5xD
✅ HAM Titandrill: Our process-reliable 3xD deep hole drill with internal cooling
Vollmer Werke GmbH and NUM AG new in the digital process chain of HAM Präzision
+++ HAMmer partnerships +++
We are expanding our digital process chain in the field of grinding with innovative partnerships.
These partnerships create new dimensions in the digital process chain:
- Modelling of special tools
- Production of special tools in minutes
- Implementation of customised special tools directly in the digital process chain
- Regrinding of tools directly in the digital process chain
A warm welcome to our new partners VOLLMER WERKE Maschinenfabrik GmbH and NUM AG. The Vollmer grinding machine Vgrind ARGON and the Numrotoplus software enable the production of special tools in minutes.
Aluminum is in the Air
Are you looking for a milling tool with higher feed rate and better chip evacuation? Again! Wir HAM die Lösung!
Look at our great new Alu Cut with unique internal cooling that we have developed:
- Suitable for dry machining, minimum quantity lubrication as well as with cooling lubricant.
- 40% faster machining time.
- Better chip removal and no vibrations due to HSF surface treatment and centralized internal cooling
- Suitable for immersion in a ramp up to 45°.
New titanium tools
Almost as light as aluminum but stronger than steel – these are the properties of titanium. Titanium is becoming an increasingly important factor in machining and HAM has launched a new titanium program on the market. Our Titan milling cutters are successfully used in the medical technology, the aircraft and automotive industry.
HAM knows that cooling the workpiece and tools is important to prevent overheating. We are using a special cooling lubricants because it offers a good lubricating effect and high cooling performance.
New partner in our showroom: Rotoclear GmbH
Once again we welcome a new partner in our showroom.
Rotoclear is a modern start-up with the experience of a traditional company.
The systems create clear insights where users are otherwise denied a view through liquids or particles. With the camera it is possible to stream directly from the machine via the browser.
Unobstructed vision provides visual information that forms a valuable insight to make processes safer, more reliable and more efficient.
We use the leading camera system Rotoclear C2, which not only impresses with its robustness, reliability and sophisticated design, but also because installation, operation and maintenance are significantly easier than with comparable products.
The good cooperation with Rotoclear provides us with a continuously high performance of our digital process chain, for which we would like to thank our newly acquired partner.
In this way, you will be able to follow our technology workshops conveniently from a distance in the future.
