In present scenario most of airframe components employ aluminum alloy materials having wall thickness of 1.2 to 3mm. With advancement of manufacturing techniques such as high speed machining, it is possible to machine components with wall/floor thickness up to 0.3 to 0.5 mm with high aspect ratio. The aim of making such parts is to reduce weight of payload. The machining of monolithic structure involves removing of material up to 95% from the raw material. The objective of the study is to achieve maximum material removal rate without compromise on geometry, dimensional accuracy while machining the part. This paper proposes a working methodology for high speed machining which includes efficient process planning, based on static and dynamic analysis. This paper provides insight knowledge of selection of cutting tool, fixture design, clamping method, cutting process parameters; machine tool and computer aided manufacturing (CAM) strategy, optimum stock for minimal bending and distortion. This technology has been demonstrated in hexagonal test specimen of 0.5 mm thin wall and also proven on the indigenous developed global positioning system (GPS) components.
Using Stereolithographic Printing to Manufacture Monolithic Microfluidic Devices with an Extremely High Aspect Ratio