How to Eliminate Visible Lines in Aluminum Frame Corners?

[yanikomer]

I am trying build a frame in mass production with the aluminum profiles but always have the problem at the mating region of the profiles. As you see in the picture, there is always a line at the mating region of the profiles.

Is there anyone who can help me about this problem? Do you know any process to get rid of it or any other solutions about hiding this line?

Many Thanks...

yanikomer

 

[Mech_Engineer]

The only way to hide the joint would be to weld it solid and then grind it down, or cover it with another part. Is being able to see the joint really a problem?

 

[Unrest]

I used to work with light extruded light fittings and we made all the corners 45degrees so even though you can see it, it looks like part of the design.

 

[yanikomer]

Thank you for your answers Mech_Engineer and Unrest.

This is a problem, because users touch this place of the product and feel a level-difference between the surfaces of the profiles. this is the real problem.

The profiles are produced as grinded and the process about grinding all edges of the frame after assembly is a real challange.

45 degree has also same problem while the user touches this place.

Stilll waiting for magic solutions.

Many Thanks...

 

[Mech_Engineer]

The only way you can make it "perfectly" smoth is to weld the joint and grind it flat. Is the concern purely asthetic, or are you trying to make sure the edge isn't sharp?

 

[yanikomer]

The concern is purely asthetic and the view of this section of the frame must be perfect.
Maybe we can find a solution to make the two difference surface coplaner.

 

[Mech_Engineer]

If the two parts are coming up with slightly different heights, you should take a look at your tolerance stackup between the two parts.

 

[yanikomer]

do you know any way to make the difference between profile levels compensated ?

 

[Q_Goest]

If I have a feature I don't want to stand out like that, rather than try to hide it, it's often easier to highlight it. In other words, don't try to hide it, try and change it so it looks ornamental. In this case for example, rather than try and eliminate the joint, accentuate it by tapering the end that butts up against the side. You could simply chamfer the end, leaving a triangular depression along that face, or put a groove there. You could also cut the ends at 45 degrees and do the same thing. Or go even further and put brick like notches along the edge of one of the parts. Or scoop out a radius. Make it look like it's supposed to have an edge there instead of trying to hide it.

 

[Ranger Mike]

GLUE IT

depending upon the load, check out air craft adhesive glue..our driver is an air craft mechanic of 30 years and he used some air craft glue for the aluminum floor pan and that stuck is almost impossible to separate..
check out 3M..and the web