The effect of cutting tools geometry during roughing operation for pocketing profiles of aerospace part

Yusri, Muhamad Nazhif (2024) The effect of cutting tools geometry during roughing operation for pocketing profiles of aerospace part. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

During the course of this project, in-depth research was carried out to increase comprehension and knowledge by collecting data from a variety of sources, including journals and articles connected to the " The Effect of Cutting Tool Geometry During Roughing Operation For Pocketing Profiles of Aerospace Part." This study aims to investigate the impact of cutting tool geometry, specifically the helix angle and number of flutes/teeth, on the machining performance and surface quality of pocketing profiles for aerospace components. The objective is to optimize tool geometry to address issues related to surface roughness, tool wear, and dimensional accuracy, thereby enhancing productivity and reducing expenses in the aerospace industry. The research focuses on three-axis milling of closed pocketing circular and rectangular profiles using CATIA V5 as the primary CADCAM software. The experiments utilize genuine aircraft aluminum alloy Al-6061 T651 material, commonly employed in aerospace applications. The cutting conditions remain constant throughout the experiment, and a range of cutting tools with different geometries are employed. An uncoated solid carbide end mill with a diameter of 8mm and various flute configurations (2, 3, and 4 flutes) are used, considering helix angles of 10°, 30°, and 50°. Pocketing operations are performed using the DMGMORI DMU 60 Evo, a CNC Milling Machine 3-Axis. The study evaluates surface roughness using the Mitutoyo STJ-410 surface roughness analyzer, while tool wear and dimensional accuracy are examined using the Nikon MM-80 measuring microscope. The experimental results will provide insights into the effect of tool geometry on surface finish and aid in identifying the most optimal tool geometry for milling pocketing profiles in the aerospace industry. By addressing surface roughness, tool wear, and dimensional accuracy issues through optimized tool geometry and improved machining strategies, this research aims to enhance the quality, productivity, and cost-effectiveness of pocketing operations in the aerospace sector, leading to potential reductions in material waste and increased overall efficiency.

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