Common Problems in Busbar Machining
1. Tool Sticking and Built-Up Edge: Aluminum chips easily stick to the tool, affecting surface finish. Sharp tools and coolant are required.
2. Deformation of Soft Materials: Excessive clamping force causes indentation, and cutting forces cause vibration deformation (need to optimize clamping force and feed rate).
3. Surface Scratches: Aluminum has a low surface hardness and is prone to scratches during transport or machining (protection of contact surfaces is required).
4. Difficulty in Burr Control: Drilling/cutting edges are prone to burrs, requiring deburring processes (such as skiving and vibratory polishing).
5. Oxide Layer Effects: Hard aluminum oxide spots on the surface accelerate tool wear. Cleaning (such as chemical cleaning) is recommended before machining.
