Modelling effect of cutter geometrical feature for shoulder milling of thin deflecting wall

Mohamad Azmi, Helmi Affendi (2014) Modelling effect of cutter geometrical feature for shoulder milling of thin deflecting wall. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

	Text (24 Pages) Modelling effect of cutter geometrical feature for shoulder millingof thin deflecting wall.pdf - Submitted Version Download (654kB)
	Text (Full Text) Modelling effect of cutter geometrical feature for shoulder milling of thin deflecting wall.pdf - Submitted Version Restricted to Repository staff only Download (14MB)

Abstract

Machining of aerospace structural components involves several thin-wall rib and flange sections. These thin-wall sections are dictated by design consideration to meet required strength and weight constraints. These components are either forged or cast to the approximate final shape and the end milling process is used to finish machine the parts or the component is machined from a solid block of material by end milling with roughing and finishing cuts. During machining, the cutting forces cause deflection of the thin-wall section, leading to dimensional form errors that cause the finished part to be out of specification. Cutter geometry such as helix angle and number of flute play an important roles on the machining performance and should be methodically analyzed. For the thin wall milling, the knowledge on the effect of cutter geometry is vital since it will help to control the cutting forces. Thus, this project aims to predict the effect of cutter geometrical feature when machining thin-wall component by numerical analysis. The model is developed to take into account the tool geometries on material removal process during machining process. The prediction values have been validated by machining tests on titanium alloys parts and show good agreement between simulation model and experimental data which confirmed the model validity. The data generate from the model are then used as an input for statistical analysis to evaluate the effects of cutter geometry on surface error. From the statistical analysis it showed that less number of flutes and high degree of helix angle gives minimum displacement to the thin-wall component.

Actions (login required)

View Item