Investigation On The Effect Of Machining Strategies On The Surface Finish And Dimensional Accuracy Of Five-Axis Flank Machining Of Curvy Angled Shapes (CONVEX)

Ahmad Syazili, Md Din (2015) Investigation On The Effect Of Machining Strategies On The Surface Finish And Dimensional Accuracy Of Five-Axis Flank Machining Of Curvy Angled Shapes (CONVEX). Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

Machining strategist is a 3D CAM product that generates optimum roughing and finishing CNC tool paths from the complex shapes generates by all major 3D modelling systems. This research mainly study about the machining strategies offered in Computer Aided Manufacturing (CAM) programming. In milling process, there are two types of cutting strategy which are point milling and flank milling. In this study, only the flank milling is main focused. The purpose of this research is to find the best machining strategies namely Tanto Fan, Combin Tanto, and Combin Parelm resulting the most accurate dimensional accuracy and surface finish. Those three machining strategies selected were the options of tool axis given by CADCAM software Catia. Furthermore, the simulation from Catia shows a little different and sometimes shows same result of simulation even though users have changed the selection of tool axis. Besides, users always confusing in selecting the most suitable tool axis. An actual sample called End Cap was selected and it was an actual aerostructural components. The type of raw material used was aluminium A6063. A6063 is one of the highest strength materials, commercially available alloys with fair corrosion resistance and machinability. Typically used for aircraft skins, cowls and structures. For analysis, Coordinate Measuring Machine and surface roughness test was used to identify the significant effect of the factors on the response. As for the result, the best machining strategies for the part sample based on the dimensional accuracy was Tanto Fan. Meanwhile, the best machining strategies suitable for the part sample based on the surface roughness was Combin Parelm. The results obtained relied on a few conditions that have been discussed in this report. The conditions are believed to have any chances to influence the result for this study. There were two possible factors that contributed to the mentioned result which was related closely to the tool trajectory and vibration during machining process.

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