Machining operation (fillet) on Aluminium block
Machining operation (fillet) on Aluminium block
(OP)
Hi all,
I have Aluminium block which is drilled from 2 sides at 90°.
Problem:
A sharp edge is created at intersection of both the operation.
Due to this there is a pressure drop. We did a CFD analysis for this.
So for this we need to add fillet/radius at the intersection zone. (on the edge)
I need to know, what is the process by which i can get the fillet at the zone.
Also need to check its feasibly for high volume parts.
Please refer the attached pdf which indicate the requirements.
regards,
Sundeep
link to file:
http://files.engineering.com/getfile.aspx?folder=3...
I have Aluminium block which is drilled from 2 sides at 90°.
Problem:
A sharp edge is created at intersection of both the operation.
Due to this there is a pressure drop. We did a CFD analysis for this.
So for this we need to add fillet/radius at the intersection zone. (on the edge)
I need to know, what is the process by which i can get the fillet at the zone.
Also need to check its feasibly for high volume parts.
Please refer the attached pdf which indicate the requirements.
regards,
Sundeep
link to file:
http://files.engineering.com/getfile.aspx?folder=3...





RE: Machining operation (fillet) on Aluminium block
RE: Machining operation (fillet) on Aluminium block
RE: Machining operation (fillet) on Aluminium block
Whilst it will not put a true radius or chamfer on have you considered abrasive flow machining? Basically it involves forcing a type of abrasive “putty” through the inside of parts to improve the surface finish / remove burrs, similar end product to “rumbling”.
RE: Machining operation (fillet) on Aluminium block
Ted
RE: Machining operation (fillet) on Aluminium block
Or go for the abrasive flow machining.
Depending on the particular aluminum alloy in use, you might be able to machine the elbow bore in a straight condition and bend the part after machining. You will probably have to use a larger bend radius than you have shown, and neck down the outside pre-bend.
If you are at a fairly early stage of development, you owe it to yourself to spend some time in a junkyard and look at how automotive air conditioning stuff is assembled from aluminum tubing with end fittings that are coined or formed or machined from extrusions, and everything crimped and brazed and then bent, etc.
Mike Halloran
Pembroke Pines, FL, USA
RE: Machining operation (fillet) on Aluminium block
I would not try to change the corner inside the part. They will have a hard enough time removing the burrs in the area you are concerned about. The bending concept of MikeHalloran is also interesting.
Bill
RE: Machining operation (fillet) on Aluminium block
Most are suitable to CNC cycle programming which can be done in large quantities with consistent results. There are a few other internal deburring tools out there which might work the same. Call some vendors, get them to bring samples by and help with the application.
good luck.
RE: Machining operation (fillet) on Aluminium block
If you're going to high volumes, you may also want to look at making the entire block as an aluminum casting and machining any threads for fittings, etc afterwards.
You can achieve the internal fillets with a core fairly easily.