Machinability study of roughing machining strategies for pocketing features of an aerospace

Sabardan, Muhamad Mahfiz (2023) Machinability study of roughing machining strategies for pocketing features of an aerospace. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Computer-aided manufacturing (CAM) is the efficient application of computer technology in manufacturing planning and control. Aerospace, biomedical engineering, optics, and MEMS all require the fabrication of parts with high dimensional precision and surface profile, making production difficult. The main aim of this research is to evaluate the effect of roughing strategies namely concentric and helical (multipass mode) on the surface roughness and tool wear in machining pocketing profiles of an example aero structural component. and to determine pand ropose the most optimum roughing strategy to machine pocketing profiles of an example aero structural part using an actual aerospace standard material (Aluminum 6061 series) with respect to the surface roughness and tool wear analysis utilizing roughing operation offered by CATIA V5. Surface roughness is an important property that indicates workpiece quality during the milling process. Meanwhile, dimensional accuracy is a crucial aspect that determines the acceptance of each machined part. The type of cutting tool used in the milling machining process, tool geometry selection, and cutting parameters are all important factors in achieving good surface finishing and meeting part tolerances. In this research, there are two main machining strategies that will be focused on: multipass and helical. In Catia V5, users could choose the direction of the tool path. There were some elements that required the tool path to be carefully considered during the machining process. As a result, selecting the proper cutting or machining strategy is critical to ensuring the end result of machining. This project will utilize a CNC milling machine with a 3-axis to perform the physical machining. In this project, there are two types of measurement involved, which are surface roughness and tool wear. The tool wear was studied using microscopy analysis on a rough image of the tool that was obtained via a Nikon MM-800 optical microscope. Measurement is a method of measuring something using additional equipment. Ra, Ry, and Rz are the three parameters derived by surface roughness testing. The value of Ra was investigated as a parameter for surface roughness. However, because Ra is utilized as a global measurement of the roughness amplitude on a profile, only it was studied. Ra is the mean roughness of a piece of standard length sampled from the roughness chart's mean line. Aside from that, the pieces were divided into two halves, one circular and the other rectangular.

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