알루미늄 절단 기술: 기본부터 고급 방법까지

In numerous industries, such as the automotive or aerospace industries, electronics or construction, aluminum cutting is a significant process. The lightweight strength of aluminum and its corrosion resistance have made it a preference to manufacturers as well as to do-it-yourselfers. However, aluminum has to be cut with proper tools and a defensible strategy, so as to attain perfect cuts without destroying the material. Being a hobbyist or a professional fabricator, this knowledge will make your choices better, mistake-free, and the most excellent results in every aluminium cutting project.

The hand tools, power saws and more recently, more sophisticated such as the aluminum laser cutting, are some modes of aluminum cutting. Laser-cut aluminum is a new and currently fast-growing alternative to classic techniques (that can complement more basic shapes). In case you intend to incorporate in your next project the so-called aluminium laser cutting, we will also present some design suggestions and cost-conscious recommendations.

Here in this article, we will see all about what you need to know about the process of aluminum cutting, starting with the ancient ways of doing it, to the new form of laser process. We will discuss the advantages and disadvantages of each of the techniques, typical issues of the so-called laser cut aluminium, safety precautions to consider and which tools and equipment will be required. 

What Is Aluminum Cutting?

Cutting of aluminum material is the act of shaping, trimming or cutting aluminum material pieces, or proportioning the material into particular sizes or shapes through different tools and strategies. Since aluminium is light, strong, and corrosion-resistant, it finds its applications across a variety of industries: construction, aerospace, automotive, electronics, home DIY projects, etc.

A lot of cutting methods of aluminium exist, depending on the thickness of the material, the shape wanted, or the required accuracy. Possible ways are:

• Manual Cutting: This is done with manual tools such as hacksaws or shears, which are good to use in simple cuts and small jobs.

• Mechanical Cutting: With the use of power machinery such as the circular saws, jigsaw, or CNC machine-serves bigger or repetitive work.
• Laser cut aluminium: This is a very defined system where laser beams provide precise laser cutting to create intricate or detailed shapes at fast rates and without dirt.
• Aluminium Laser Cutting: This is an offshoot of laser cutting modified to work best with aluminum, fibre lasers, and nitrogen assist gas to deal with the reflectivity and heat conductivity of aluminium.

Pros and cons can be attributed to both of them, yet about the intention of cutting aluminum, there can never be a difference, and that is to get clean, precise and safe cuts with minimum waste and maximum productivity.

Some of the Main Properties of Aluminium

We cannot ignore the material before we start discussing the process of cutting it in the name of aluminium cutting. Aluminium is soft in its strength and more robust than numerous metals. It transfers heat fast, and this may be a source of challenge during the use of the cutting tools. Left unchecked, aluminium can clog up tools or give a poor finish.

These properties have led to the involvement of various methods that facilitate in the cutting of aluminum in a better and precise manner. The selection of the method is based on the thickness of material, precision needed and the tools available.

Conventional Names for Aluminium Cutting

Before the invention of advanced machines and laser technologies, aluminium cutting was performed using primitive, manual methods. Although such techniques cannot bring the accuracy of the modern instruments, they are still commonly used in small projects, repairs and where cheapness and simplicity are essential interests. What about the old ways of aluminium cutting that have survived the test of time?

1. Hacksaws

A hacksaw is a low mechanism, hand operated equipment manufactured to cut aluminium. It involves finely toothed blade which cuts soft metals. It is suitable in thin sheets, pipes or bars and cutting straight cuts on small aluminum pieces.

장점  

• Readily available and low-priced  
• No power required  
• Good straight cutting  

단점  

• Slow, strenuous  
• Less precise powered tools

2. Aviation Shears and Tin Snips  

Tin snips, or aviation shears, can be used on thin aluminium. They are available in straight-cut, left-cut and right-cut versions of these scissors-like tools designed to work in sheet metal and, therefore, allow working with curves and angles that are very tight.  

장점  

• It is very light and user-friendly  
• Excellent when one needs a quick cut into the sheet metal  
• Very good when cutting angles and curves

단점  

• Only thin aluminium is available.  
• The sides may be jagged  
• It may be rough on the hands after considerable use

3. Handheld Nibblers  

A portable nibbler nips off tiny bits of the aluminium as it travels over a line. It is perfect to cut curves, circles, or various patterns on sheet aluminium.  

장점  

• Pin-sharp detail cut accurately for small cuts  
• Ability to support curves and irregular shapes  
• Makes less distortion as compared to snips

단점  

• Not as fast as powered ones  
• It leaves small fragments of waste  
• Gets practised to be used well

4. Jigsaws  

A jigsaw is a power type of tool which can move in the up and down direction. it can cut through aluminum sheet or tubing when supplied with a fine-tooth metal blade. Jigsaws are quite handy in cutting customized shapes or curves.  

장점  

• Able to deal with curves and corners  
• Visibly transportable and comparatively cheap  
• Suitable with hobbyists and professionals

단점  

• Has the capability of generating vibration  
• Must be well-controlled to eliminate the rough edges  
• Does not suit very thick pieces

5. Circular Saws  

If a thicker sheet of aluminium is to be cut, a non-ferrous metal blade section can be mounted on a circular saw. These are the tools which are commonly used in construction and fabrication to cut straight lines.  

장점  

• Quick and smooth, long, straight cutting  
• Can work with thick materials  
• A good one with proper guides

단점  

• Produces fire and sparks  
• Must have blade lube to keep from gumming up  
• Precautionary measures are needed

6. Bandsaws  

A bandsaw is a type of saw and incorporates a continuous looped blade that makes it suitable when cutting thicker stock and when straight lines or Geometry are needed. A lot of metal shops use bandsaws due to their flexibility and speed.

장점

• Suitable for cutting heavy or thick aluminium.
• Cano delivers sanitised cuts as compared to handheld tools.
• Comes in portable and non-portable machines.

단점

• Costly as compared to simple tools.
• Uses space and has to be set up.
• It is not good for complex shapes.

Best Traditional Cutting Practices

• Hold the material using a clamp to maintain it still.
• Cutting fluid or wax can be employed in reducing heat and extending life.
• Take your time; going too fast will leave sharp edges or otherwise make the cut incorrect.
• Clean the edges with a file or sandpaper to remove sand spots which are sharp.

Typical Issues of Laser Cutting Aluminium 

1. Reflective Surface

On older CO 2 machines, lasers are reflected by aluminium, and fewer watts irradiate the material.
Solution: Go with fibre lasers and adjust the angle or coat it.

2. Rough or hough Edges

The edges are scorched or jagged on occasion.
Fix: An alternative would be to use nitrogen rather than oxygen in the fixing phase, also to change the laser speed and power.

3. Heat Warping

Aluminium can conduct heat very fast, and therefore, thin layers can get curved or warped during the cutting process.
Solution: Employ less power and speedier speeds. Crimp the workpiece.

4. Sticky residue, Dross 

Molten aluminium may attach to the bottom edge, resulting in a rough termination.
Fix: Run high pressure of gas and maintain a clean as well as straight nozzle.

5. Unfinished or Unsuccessful Cuts

The laser, in some cases, does not pierce well, or it leaves parts incomplete.
Repair: Wash the metal, upgrade the software and check all worn components.

6. Discolouration and Oxidation

Oxidation tends to darken or wear out a cut surface.
Fix: clean the edges afterwards (if necessary) with nitrogen gas.

7. Cracks on the Edges

Cuts that are very fast or hot may produce minute cracks and make the aluminium weak.

New Technologies: Laser Cut Aluminium

In laser-cut aluminium, a laser beam is directed at the metal to fuse or evaporate it along the intended directions, providing accurate and neat cuts.

Benefits of Lasers on Aluminium

1. Precision: Laser cutters have very close tolerances and exquisite designs.
2. Smooth Finish: Minimum or no touching up is needed when it is cut.
3. Minimum Material Wastage: There is minimum wastage of material due to a small kerf (cut width).
4. Automation-Friendly: The whole procedure is regulated by the use of CAD files, making it efficient.

Uses of Aluminium Laser Cutting

• Automotive Manufacturing: In the case of lightweight structural components.
• 항공우주: Cutting of aircraft parts.
• Architecture: Ornamental panels and facades, and signs.
• 전자 제품: enclosures and thermal control products.

Since the procedure of aluminium laser cutting enables duplicable and reliable cuts, it is preferred when repeatable cuts are imperative in the setting.

Methods For Aluminium Cutting 

Both ways may be preferable depending on your needs. Make up your mind based on this chart:

Here is Table 1: Methods For Aluminium Cutting 

Safety First

When you are working with hand tools or highly technical laser systems, safety must be your main concern. Lack of safety may turn out in severe injuries or permanent health issues.

Eye Protection: Use of Safety goggles should always be used. Flying bits and laser beams are dangerous to your eyes.
Hearing Protection: Power tools are quite vociferous. Use earmuffs or high-quality earplugs.
Ventilation: Severing of aluminium, particularly by power lasers, causes toxic vaporisation. The works of cutting aluminium (aluminium laser cutting) are carried out in a well-ventilated place or the presence of fume extractors.
Proper Handling: Aluminium can be very sharp when they are cut. Be careful with the parts and wear gloves to prevent cuts.
Machine Safety: In the case of laser-cut aluminium, ensure that the machine is in good condition and the laser is contained, and the emergency switch can be reached.

Good safety not only keeps you safe but also all the people around your work area.

The Selection of the Correct Instruments

When you are undertaking a DIY project or an industrial build-back, it is necessary to have the correct tools. All this depends on the technique to use and the accuracy you require.

Manual Work

Select hard steel hacksaws or snips. They are cheap and ideal to be use in small jobs or emergency repairs. Blades always need to be sharp.

In case of Power Tools

Apply round saws or jigsaws with carbide-tipped blades. There have to be good clamping arrangements in place to clamp the aluminium in place, and any lubricants should be used to minimise heat and blade life.

In the case of Laser Cut Aluminium

Apply laser regulations that are managed and have the highest level of precision (CNC). Having the correct gas assist (nitrogen here) and alignment tools will get you optimal results. This technique is ideal for precise and fine cuts.
Note that regular servicing of the tools eliminates downtime, makes them perform better, and cuts clean and safely. Either doing the manual or the so called aluminum laser cutting, maintenance of tools is a major difference.

Laser Cutting Design Tips

The success of any project in the concern of aluminium cutting lasers is determined by good design. This is because poor designs may cause warping of the designs, cracks or wastage of material. Do the following:

• Shun Sharp Interiors: Apply rounded corners to ensure that no stress builds up and cracks, particularly with thinner sheets.
• Kerf Width allowed: A small quantity of material is cut by the laser, called the kerf. Incorporate this in drawing your CAD drawings to get the right dimensions.
• Heat Expansion: When being cut, aluminum has the ability to stretch because of heat. Do not have parts very close to another, this will lead to distortion or undesirable overlaps.
• Do not go too thin: Areas of very thin or fragile material would not resist the high temperature of “aluminium laser cutting”. Stiffen fine linework or use a heavier sheeted paper.
• Exercise Your Plans: Use a scrap of aluminium to test a laser by design before producing it in large quantities, so that any flaws are noticed earlier.

The Steps Prevent Rework and Lead to the Manufacture of Quality End Products

The price of aluminium cutting varies with a number of factors. The appreciation of factors that influence the price should enable you to plan and stay within budget.

• Material thickness: Thick aluminium requires increased laser power and low speed, which increases the expenses incurred when it comes to the production of the laser-cut aluminium.
• Reduce complexity: Straight-forward cuts take less time and cost less. The complicated designs are lengthy and require precision movement of the machine hence costly.
• Quantity: The more that is ordered, the cheaper the price on an individual part. By ordering a large quantit,y you will be able to utilise material and machine time more effectively.
• Cutting technique: Aluminium is cut manually (with aluminium cutting), which is less expensive to perform, and less precise. Aluminium laser cutting costs more initially, is time-saving and reduces the amount of finishing work.
• Final finishing: There is less sanding, polishing or reworking since laser cuts are rather clean, requiring little or no cleanup on the final part, reducing time and labour consumption.

Laser cut aluminum may be initially costly to look at but proves to be cheaper in case of high preciseness or very large applications. Waste, turnaround, and increases in results are minimized through good planning and design.

환경적 고려 사항

Contemporary surgeries, such as aluminium laser cutting, are usually more sustainable. Laser cutting is efficient and thus reduces waste, and most of the systems recycle aluminium scrap. Moreover, newer laser machines consume less energy and produce fewer emissions as compared to older methods. Aluminium is also very eco-friendly because recycling is extremely efficient as compared to raw production, and only 5 per cent of the energy is used, thereby making it one of the most eco-friendly metals.

Aluminium Cutting Technology in the future

Once again, technology continues to transform aluminum cutting. Look for:

• Real-time adjusting AI-integrated laser cutters.
• Hibrid machines involving laser and mechanical techniques.
• Laser cutting of shaped and curved parts of aluminium through 3D cutting.
• Increased automation and robotisation in the production lines.

The popularity of lightweight and long materials will attract more people will look forward to an increased use of aluminum laser cutting.

결론

The importance of selecting the appropriate technique of aluminum cutting cannot be underestimated, regardless of whether you are working on a car, a facade, or even a custom part. Ranging between hot tools and modern high-tech solutions, known as aluminum laser cutting, there are certain positives and drawbacks associated with them. With the current advancement in technology, aluminium laser cutting has acquired the ability to come up with precise, efficient, and scalable solutions all over the world.

Never choose the method which does not fit your ambitions, materials and funds and put the emphasis on safety and sustainability. The future of the aluminium cutting has never been this bright, clean as well and sharp. It provides unsurpassed precision and the best smooth finishes with high turnaround and would fit perfectly in industries where things need to be accurate and delivered within time. Most of these challenges can be eliminated or minimised with proper set-up, equipment and understanding.

Because material and technology are changing, aluminium cutting will become more precise and available with time. If you are working on close-fitting components and using the real-world aluminium laser cutting processes or just taking out a saw in a shop, knowledge is power.

Frequently asked questions 

1. Which is the most efficient way of cutting aluminum?

The correct procedure relies on what you require:

• The simple ones may be done either manually or by the use of power tools.
• The best work with precision is with the use of aluminium laser cutting.

2. Is it safe to cut Aluminum with a laser?

Yes, in case you use precaution measures, including ventilation, eye protection, and proper use of the machine.

3. How can aluminum be laser-cut more difficultly than steel?

Aluminum does reflect light easily and also transfers heat fast, hence making aluminium laser cutting hard.

4. Can a Laser cut thick aluminium?

Yes, but you will require a potent fibre laser and high-pressure gas. Dense material may be able to reduce the speed of laser cut aluminum.

5. Is cutting aluminium costly?

Prices are different: Cost estimation is more expensive initially sometimes saves time and wasteful material in large or complicated works, Aluminum laser cutting.