Effects Of End Mill Helix Angle On Accuracy Of Thin-Walled Aluminium Ribs

Koh, Aries Chin Chin (2015) Effects Of End Mill Helix Angle On Accuracy Of Thin-Walled Aluminium Ribs. Project Report. UTeM, Melaka, Malaysia. (Submitted)

Text (24 Pages) Effects Of End Mill Helix Angle On Accuracy Of Thin-Walled Aluminium Ribs.pdf - Submitted Version Download (418kB)

Abstract

Aerospace industry contains high usage of thin-walled aluminium ribs. The machining of aerospace structural components is a critical process due to high flexibility and it involves several thin-walled ribs section. The components that contain thin-walled ribs section must be considered with the design consideration to meet required strength and weight limitation. Generally, these structural components undergo casting process to cast out the approximate final shape and the end milling process steps into secondary process whereby involves finishing cuts. Dimensional accuracy or deformation results in the low precision of dimensions are more likely to occur in the machining of thin-walled components. The available study develops adequate end milling cutting force model to analyse the surface dimensional accuracy of thin-walled workpiece. The cutting forces that produced during machining is one the factor causes the deflection of the thin-walled section, and consequently lead to dimensional accuracy that cause the finished part to be failed from the specification or failure. The end mill with different helix angles are modelled that can be more accurately stimulate the specific geometry and structural behaviour of the cutter. In this study, a new methodology is investigated and presented to become a solution for the prediction of wall deflection on thin-walled section during milling process. Referring to the existing research for machining thin-walled components, the study is related only to the focus of the process planning and the effects of cutter geometric feature is often out of the range of studies. In technically, tool geometric feature is a major factor that can influence on the cutting performance during milling process. The experiment testing is carried out by using aluminium alloys parts that reduce the wall deflection and thus improving the component accuracy.

Actions (login required)

View Item