“Zinc has a relatively low hardness that reduces tool wear during machining and enhances the efficiency of production runs. These attributes contribute to zinc’s versatility in various manufacturing applications”
Among various machining materials, zinc is known for its corrosion resistance, machinability, ductility, conductivity, and considerable mechanical strength. Zinc Machining provides numerous manufacturing solutions across all sectors. The availability of various alloys with unique properties and their compatibility with all operations of cnc machining is a significant advantage for industries.
Moreover, selecting the right zinc alloy grade and machining processes is essential to meet the specified design features and dimensions. In this article, we will discuss the zinc machining processes, common alloys, tooling, and other related areas.
Let’s start it!
Properties of Zinc As a Machining Material
Zinc is a popular material among different cnc machining materials. In the current manufacturing scenario only iron, aluminum, and copper are above the zinc in the list of most used raw materials.
Zinc as a machining metal
Although natural zinc is rarely used for machining, the combination of zinc with other metals ( alloys) is machined into a detailed shape. This non-magnetic metal is easy to machine and maintains the design’s dimensions precisely. The parts can be plated with various surface treatment techniques.
Subsequently, zinc die cast parts are subjected to machining to remove the excessive material and give them final shape.
Try Prolean Now!
Zinc Machining Processes
Next, which cnc machining process is suitable for your zinc machining project? Milling, Turning, Drilling, EDM, Laser cutting, or another one? Each of these processes has different machining capabilities and applications. In some cases, you might also need to use these multiple operations for complex designs.
CNC Milling
The CNC milling process involves rotating cutting tools to shape the zinc workpiece into flat or complex contours. Zinc milling has numerous applications in all industrial manufacturing sectors.
CNC Turning
In this CNC process, the zinc bar rotates at a high speed, whereas the tool post or collet moves in linear & vertical motion to feed the rotating work. It is suitable for cylindrical or conical-shaped zinc parts. Often, turning & milling can be combined in a single machine setup, called the turn-mill process. It allows to creation of complex zinc designs without changing the workpiece from one machine to another.
CNC Drilling
CNC drilling on any zinc material involves rotating drill bits with helical-flutes structure. The drill bits for zinc drilling are typically made from carbide or other hard materials. You can drill the holes on zinc workpieces by choosing the suitable size (⌀)of bit.
Laser Cutting
The laser cutter uses a high-temperature beam of laser that melts and removes the material according to 3D design. The CNC laser cutter can cut and craft the zinc into intricate shapes and patterns with accuracy.
EDM Machining
Electrical discharge machining(EDM) is comfortable with every machining zinc alloy live every other conductive material. It involves the use of copper electrodes to discharge the current with a zinc workpiece. Once the electric arc is generated from the discharge between the electrode and zinc inside the dielectric, it erodes and vaporizes the material to shape the desired cut or cavity.
Zinc Alloys for Machining
Traditional die-cast alloys, zinc-aluminum alloys, ACuZinc, and other zinc alloy material categories are used in the machining process.
Zinc alloy parts
1. Zinc Aluminum Alloys
Zinc aluminum or ZA alloys include aluminum as alloying elements ( usually a higher amount than in Zamak series grades). The aluminum content enhances the corrosion resistance, strength, and hardness. The grades of ZA alloys are ZA-8, ZA-12, ZA-27, etc.
2. Zamak Series Zinc Alloys
The Zamak alloy grades contain aluminum, copper, and magnesium. These alloying elements
enhance the mechanical and electrical characteristics of zinc. Zamak 3, 5, and 7 grades are the most popular ones in zinc machining.
- Zamak 3: Considerable strength, toughness, hardness, and ductility. It is used for decorative items, industrial components, electronics parts, etc.
- Zamak 5: It offers more strength and conductivity than zamak3 and contains more % of copper than Zamak 3. Zamak 3 machining can make durable parts.
- Zamak 7: High strength and formability due to a lower % of magnesium in alloying composition.
3. ACuZinc Alloy
It is the zinc alloy with copper and aluminum, both combined to improve with zinc the mechanical and electrical properties. This Zinc alloy material offers excellent mechanical properties, including high tensile strength and impact resistance. You can machine it for complex and thin-walled components.
Applications of Zinc CNC Machining
CNC machined zinc product
The zinc-machined parts and products have versatile applications, from high-stress applications to electrical connectors and medical components. Moreover, the options of machining grades allow to manufacture of the parts for diverse applications, fulfilling unique & complex requirements.
The table below summarizes the common applications in brief;
| Industry | Benefits (Why Use?) | Application Examples |
| Automotive | High strength-to-weight ratio, corrosion resistance | Fuel systems, brackets, gears, levers, locks, clamps, etc. |
| Electronics | Excellent conductivity | Connectors, housings, switches, heat sinks, PCB shields, etc. |
| Consumer Products | Low cost, durability, and appearance | Zippers, buckles, handles, eyeglass frames, keychains, etc. |
| Hardware | Wear resistance and durability | Hinges, door locks, handles, hooks, fasteners, knobs, etc. |
| Medical Devices | Biocompatibility and easy-to-sterilize | Surgical instruments, dental tools, implantable devices, braces, etc. |
| Aerospace | High strength-to-weight ratio | Connectors, brackets, gears, hinges, clamps, etc. |
| Industrial Equipment | Durability, corrosion resistance, machinability | Gearboxes, valves, levers, brackets, cams, couplings, fittings, etc. |
Comparison with Other Machining Metals
Besides zinc alloys, other metals like aluminum, stainless, and titanium are also heavily used for CNC manufacturing. The aluminum is relatively soft and also provides faster machining cycles. Aluminum alloy grades like 6061, 6061, 6082, and 7050 are common for the machined parts. Aluminum is used for lightweight parts with high corrosion resistance and considerable mechanical strength.
On the other hand, machining titanium and stainless steels are relatively more challenging than the zinc and aluminum grades. Especially, the high hardness of titanium grades requires special tools ( like diamond-coated tips) to avoid cracks and rapid tool wear.
Furthermore, if you are more interested in CNC machining materials, check the composite machining details here.
Try Prolean Now!
Summing Up
Overall, different zinc alloy materials can be used for CNC machining projects based on the required physical, mechanical, and electrical properties; ZA, Zamak, or AcuZnic. Consequently, the chosen grade is machinable with turning, milling, drilling, and many other CNC processes.
ProleanTech is a cnc machining service provider company with an advanced factory equipped with 3, and 5-axis CNC milling machines, turning centers, drill sets, laser cutters, etc. So, we can convert your design into a functional zinc part ensuring all minor specifications and requirements. You can upload your design and request a quote to know our Zinc Machining capabilities prices.
FAQs
What are the common Zinc machining alloys?
The common zinc alloys for machining are; Zinc Alumina(ZA), Zamak series grades(3, 5,7), and AcuZinc alloys.
Can I use any tool material for zinc machining?
No, not all tool materials are suitable for zinc machining. High-speed steel (HSS) or Carbide-tipped tools are preferred due to their durability and ability to maintain sharpness. They create smooth cuts on zinc workpieces.
Where Zinc machining is used?
Zinc machining is used for producing intricate and precise components such as gears, connectors, and housings.
Are machined zinc parts durable?
Yes, machined zinc parts are highly durable. Their excellent wear resistance, dimensional stability, and corrosion protections help to sustain them for 20+ years with proper surface finishes and maintenance.
0 Comments