Machining performance analysis during roughing machining strategy of pocketing profiles using TiSiN coated end mill- Aerospace part

Balu, Thaneswaran (2024) Machining performance analysis during roughing machining strategy of pocketing profiles using TiSiN coated end mill- Aerospace part. Project Report. Melaka, Malaysia, Universiti Teknikal Malaysia Melaka. (Submitted)

Text (Full text) Machining performance analysis during roughing machining strategy of pocketing profiles using TiSiN coated end mill- Aerospace part.pdf - Submitted Version Download (3MB)

Abstract

The aerospace industry's relentless pursuit of advanced materials and manufacturing processes to optimize component production efficiency has led to the prominence of Aluminum 6061, recognized for its lightweight and high-strength attributes. In this context, the role of cutting tools and coatings in machining processes becomes crucial. Titanium Silicon Nitride (TiSiN) coatings have demonstrated significant potential in enhancing tool durability and performance during the machining of aluminum alloys.Despite acknowledging the benefits of TiSiN-coated end mills, a nuanced exploration into the intricate interplay between machining parameters, tool wear, and surface roughness in the context of Aluminum 6061 is imperative. This research aims to fill this critical gap by delving into the optimization of machining parameters, with a focus on roughing strategies for pocketing profiles, using TiSiN-coated end mills. The problem statement highlights the challenges faced in machining Aluminum 6061, emphasizing the need for precise optimization. The lack of a comprehensive investigation into the interaction between machining parameters and TiSiN coatings inhibits the realization of their full potential, hindering the development of a systematic methodology for maximizing tool life and achieving superior surface finishes. The research objectives are structured to address the identified challenges. The investigation aims to understand the effect of machining parameters, specifically cutting speed and feed per tooth, on machining results, surface finish, and tool wear during roughing of pocketing profiles for aerospace parts. Additionally, the research seeks to determine the most optimum machining parameters for TiSiN-coated end mills in the roughing operation of pocketing features. The scope of the research involves milling Aluminum 6061 T651 using a 10mm 4-flute TiSiN-coated end mill, utilizing a DMG MORI DMU 60 Evo CNC machine programmed with CATIA V5. The focus is on open pocket profiles, examining the influence of cutting speed and feed per tooth, and emphasizing the achievement of optimal surface roughness while monitoring tool wear on the end mill face.This research endeavors to contribute valuable insights that not only advance the understanding of machining dynamics but also provide practical guidelines for enhancing the performance and economic viability of aerospace manufacturing processes, thereby addressing the industry's evolving machining requirements.

Actions (login required)

View Item