New Cutter Design To Minimize Part Deflection In Machining Thin Wall Low Rigidity Component

Mohd Norazzim, Mohd Hashim (2012) New Cutter Design To Minimize Part Deflection In Machining Thin Wall Low Rigidity Component. Project Report. UTeM, Melaka Malaysia. (Submitted)

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Abstract

For aerospace structural component manufacturer, the demand for the highperformance cutting tools is pre-requisite as more than 80% of the material is cut away to produce the monolithic component. In addition, this works demand high quality surface profile as most of the monolithic component contains a thin-wall feature. Because of the poor stiffness of thin-wall feature, deformation is more likely to occur in the machining of thin-wall part which result a dimensional surface errors. Thus, this machining process needs a special cutting tool for effectively control the surface errors. This project attempts to investigate and analyse the effect of flute number of end mill cutter on the magnitude of dimensional surface errors and machining performance when machining thin-wall low rigidity part. At the end of machining, what is seen are the results of analysis of surface error, cutting force and surface roughness by using different flutes. The analysis will show that either the number of flute on cutting tool will influence the workpiece surface. In addition, cutting force is influence the surface error

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