Effects of End Mill Helix Angle on Accuracy for Machining Thin-Rib Aerospace Component

2013 ◽  
Vol 315 ◽  
pp. 773-777 ◽  
Author(s):  
Raja Izamshah ◽  
M.Yaakob Yuhazri ◽  
Mohd Hadzley ◽  
Mohd Amran Ali ◽  
Sivarao Subramonian
Keyword(s):  
High Performance ◽  
Cutting Tool ◽  
Helix Angle ◽  
Machining Process ◽  
Geometric Feature ◽  
Thin Wall ◽  
End Mill ◽  
Form Errors ◽  
Challenging Tasks ◽  
Monolithic Component

Accuracy of machined component is one of the challenging tasks for manufacturer. In the aerospace industry, machining process is widely used for fabrication of unitized-monolithic component that contains a thin-walled structure. During machining, the cutting forces cause deflection to the thin-wall section, leading to dimensional form errors that cause the finished part to be out of specification or failure. Most of the existing research for machining thin-wall component only concentrated on the process planning and the effects of cutter geometric feature is often neglected. Tool geometric feature has a direct influence on the cutting performance and should not be neglected in the machining consideration. This paper reports on the effect of helix angle on the magnitude of wall deflection. The established effects will be used for the development of high performance cutting tool for specifically machining thin-wall component.

Effects of Helix Angle on Cutting Performance for Machining Thin-Wall Aerospace Monolithic Component

2014 ◽  
Vol 699 ◽  
pp. 3-8 ◽  
Author(s):  
Abu Bakar Mohd Hadzley ◽  
Mohamad Raffi Nurul Fatin ◽  
Raja Izamshah ◽  
Ahmad Siti Sarah ◽  
Mohd Shahir Kasim ◽  
...  
Keyword(s):  
Helix Angle ◽  
Wall Structure ◽  
Thin Wall ◽  
End Mill ◽  
Workpiece Material ◽  
Dimensional Error ◽  
End Mills ◽  
Thin Walled ◽  
The Right ◽  
Monolithic Component

The thin-walled component is mostly used in the aerospace industry. During machining the thin-walled components, deflection of wall occurs and causes the surface dimensional error. This paper focuses on the effect of end mill helix angle on the surface dimensional error and surface roughness when machining thin wall structure. End mills uncoated carbide were fabricated with a difference helix angle which are 25°, 30°, 35°, 40° and 45°. The results show, helix angle 35° produce smaller surface dimensional error and smoothest followed by 40°, 45°, 30° and 25°. The smaller helix angle provided high cutting force that causes more surface dimensional error due to chatter and reduction of contact time when then end mill engage with the workpiece material. Results from this research help to guide the machinist to machine thin-wall component with the right cutting tool.

The influence of end mill helix angle on high performance milling process

2020 ◽  
Vol 34 (2) ◽  
pp. 817-827 ◽  
Author(s):  
Marcin Plodzien ◽  
Jan Burek ◽  
Lukasz Zylka ◽  
Pawel Sulkowicz
Keyword(s):  
High Performance ◽  
Helix Angle ◽  
Milling Process ◽  
End Mill

A Method for Using a Virtual Machining Simulation to Consider Both Equivalent CO2Emissions and Machining Costs in Determining Cutting Conditions

2015 ◽  
Vol 9 (2) ◽  
pp. 115-121 ◽  
Author(s):  
Hirohisa Narita ◽  
Keyword(s):  
Evaluation System ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Machining Process ◽  
Machining Simulation ◽  
End Mill ◽  
Virtual Machining ◽  
Mill Operation ◽  
Nc Program

An evaluation system for calculating equivalent CO2emissions and machining costs is developed using an activity-based model. The system can evaluate a machining process from an NC program, workpiece information, and cutting tool information, and it can then calculate accurate equivalent CO2emissions and the machining cost. The cutting speed of an end mill operation is evaluated in terms of the equivalent CO2emission and the machining cost. Based on the results, optimal cutting conditions are determined to minimize the equivalent CO2emissions and the machining cost to the extent possible.

Study on the Cutting Force and Machined Surface Quality of Milling AFRP

2016 ◽  
Vol 836-837 ◽  
pp. 155-160 ◽  
Author(s):  
Si Qi Liu ◽  
Yan Chen ◽  
Yu Can Fu ◽  
An Dong Hu
Keyword(s):  
Cutting Force ◽  
Surface Quality ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Helix Angle ◽  
End Mill ◽  
Machined Surface ◽  
Reinforced Plastics ◽  
Machined Surface Quality

AFRP(Aramid Fiber Reinforced Plastics) is widely used in the aerospace and automotive while there are many problems in machining AFRP such as furry, delamination, burns and so on. Milling experiments of AFRP have been conducted to study the influence of different helix angle (0°, 30°, 60°) and cutting tools (traditional end mill, multiple flute end mill and compression end mill) on cutting force and machined surface quality. The results indicated that the cutting force has been reduced and the surface quality has been improved with the increase of helix angle. The cutting tool structure can make greater influence on machined surface quality than the cutting parameters. A cutting tool with the structure of multiple flute or herringbone cutting edge could reduce the axial cutting force. However the cutting force is too small to cut off fibers when using a multiple flute end mill. A good processing surface can be achieved while cutting with a compression end mill or a tool with big helix angle.

scholarly journals Effect of Different Cutting Speed towards Machinability of Titanium (Ti6Al4V) Curved Thin Wall using Trochoidal Milling Path

2019 ◽  
Vol 8 (6) ◽  
pp. 3392-3396
Keyword(s):  
Cutting Tool ◽  
Cutting Speed ◽  
Machining Process ◽  
Machining Accuracy ◽  
Hard Material ◽  
Thin Wall ◽  
Machining Parameters ◽  
Body Parts ◽  
Jet Engines ◽  
Machining Force

Aircraft parts and components used a lot of titanium as the material for body parts and engines. The materials offer rigidity, strength and light in weight. This unique characteristic was the major advantages in improving the payload capacity and improving the fuel consumption of the jet engines. The problem raised during the machining process of the material. Titanium is a hard material, elastic and poor thermal conductor. As the material is hard, higher machining force is required to perform the machining. Elasticity added the difficulties as it will spring away from the cutting tool which cause the tool to rub instead of cutting that can increased the heat. Thus, machining titanium alloy is expensive and difficult. This preliminary study looks into several machinability aspects and machining parameters for curved thin wall machining profile in the research. Machining accuracy and cutting tool wears were observed during the experiments. There are two set of machining parameters for the machining trials. At the same time, this research able to recommend the suitable machining parameters analysed from the experiments.

scholarly journals Influence of End Mill Geometry on Milling Force and Surface Integrity While Machining Low Rigidity Parts

2020 ◽  
Author(s):  
Shrikrishna Nandkishor Joshi ◽  
Gururaj Bolar
Keyword(s):  
Surface Integrity ◽  
End Milling ◽  
Surface Damage ◽  
Helix Angle ◽  
Thin Wall ◽  
End Mill ◽  
Milling Force ◽  
Machined Surface ◽  
Machined Parts ◽  
Aluminum Alloy 2024

AbstractHigh precision and superior surface finish are of prime importance in thin-wall components used in the aerospace and automobile industries. In this paper, end milling experiments on aluminum alloy 2024-T351 were carried out to study the influence of end mill geometry on milling force and surface integrity of the machined parts. Machining using a 16-mm-diameter tool having a helix angle of 35° produced high force value and also generated chatter marks on the machined work surface. Furthermore, an inspection of the cutting tool indicated built-up-edge formation while machining with a 35° helix tool. Besides, surface damage in the form of surface tear was observed. Evaluation of microhardness revealed an increased value near to the machined surface in the case of two fluted 35° helix tool due to strain hardening. The results showed that lower milling force and surface roughness were obtained while machining used a four fluted end mill having a diameter of 8 mm and a helix angle of 55°.

scholarly journals A Novel Finite Element Method Approach in the Modelling of Edge Trimming of CFRP Laminates

2021 ◽  
Vol 11 (11) ◽  
pp. 4743
Author(s):  
Fernando Cepero-Mejias ◽  
Nicolas Duboust ◽  
Vaibhav A. Phadnis ◽  
Kevin Kerrigan ◽  
Jose L. Curiel-Sosa
Keyword(s):  
Finite Element ◽  
Tool Wear ◽  
Cutting Tool ◽  
Machining Process ◽  
Machining Forces ◽  
General Terms ◽  
Numerical Predictions ◽  
Composite Damage ◽  
Edge Trimming ◽  
Optimal Cutting Parameters

Nowadays, the development of robust finite element models is vital to research cost-effectively the optimal cutting parameters of a composite machining process. However, various factors, such as the high computational cost or the complicated nature of the interaction between the workpiece and the cutting tool significantly hinder the modelling of these types of processes. For these reasons, the numerical study of common machining operations, especially in composite machining, is still minimal. This paper presents a novel approach comprising a mixed multidirectional composite damage mode with composite edge trimming operation. An ingenious finite element framework which infer the cutting edge tool wear assessing the incremental change of the machining forces is developed. This information is essential to replace tool inserts before the tool wear could cause severe damage in the machined parts. Two unidirectional carbon fibre specimens with fibre orientations of 45∘ and 90∘ manufactured by pre-preg layup and cured in an autoclave were tested. Excellent machining force predictions were obtained with errors below 10% from the experimental trials. A consistent 2D FE composite damage model previously performed in composite machining was implemented to mimic the material failure during the machining process. The simulation of the spring back effect was shown to notably increase the accuracy of the numerical predictions in comparison to similar investigations. Global cutting forces simulated were analysed together with the cutting tool tooth forces to extract interesting conclusions regarding the forces received by the spindle axis and the cutting tool tooth, respectively. In general terms, vertical and normal forces steadily increase with tool wear, while tangential to the cutting tool, tooth and horizontal machining forces do not undergo a notable variation.

Surface Roughness and Cutting Force Components Evaluation in Hard Turning by Differently Shaped Cutting Tools

2016 ◽  
Vol 862 ◽  
pp. 26-32 ◽  
Author(s):  
Michaela Samardžiová
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Hard Turning ◽  
Cutting Tool ◽  
Single Point ◽  
Machining Process ◽  
Tool Geometry ◽  
Machined Surface ◽  
Cutting Force Components ◽  
Force Components

There is a difference in machining by the cutting tool with defined geometry and undefined geometry. That is one of the reasons of implementation of hard turning into the machining process. In current manufacturing processes is hard turning many times used as a fine finish operation. It has many advantages – machining by single point cutting tool, high productivity, flexibility, ability to produce parts with complex shapes at one clamping. Very important is to solve machined surface quality. There is a possibility to use wiper geometry in hard turning process to achieve 3 – 4 times lower surface roughness values. Cutting parameters influence cutting process as well as cutting tool geometry. It is necessary to take into consideration cutting force components as well. Issue of the use of wiper geometry has been still insufficiently researched.

Interference-Free Multi-Axis NC Machining of Cylindrical Cam Using Enveloping Element

2009 ◽  
Vol 419-420 ◽  
pp. 333-336
Author(s):  
Jeng Nan Lee ◽  
Chih Wen Luo ◽  
Hung Shyong Chen
Keyword(s):  
Cutting Tool ◽  
Nc Machining ◽  
Model Material ◽  
Solid Model ◽  
End Mill ◽  
Generating Method ◽  
Collision Problem ◽  
Five Axis ◽  
Cutting Path ◽  
Cutting Simulations

To obtain the flexibility of choice of cutting tool and to compensate the wear of the cutting tool, this paper presents an interference-free toolpath generating method for multi-axis machining of a cylindrical cam. The notion of the proposed method is that the cutting tool is confined within the meshing element and the motion of the cutting tool follows the meshing element so that collision problem can be avoided. Based on the envelope theory, homogeneous coordinate transformation and differential geometry, the cutter location for multi-axis NC machining using cylindrical-end mill is derived and the cutting path sequences with the minimum lead in and lead out are planned. The cutting simulations with solid model are performed to verify the proposed toolpath generation method. It is also verified through the trial cut with model material on a five-axis machine tool.

Holes Machining Process Optimization with Genetic Algorithm

2011 ◽  
Vol 460-461 ◽  
pp. 117-122 ◽  
Author(s):  
Guang Yu Zhu ◽  
Lian Fang Chen
Keyword(s):  
Genetic Algorithm ◽  
Cutting Tool ◽  
Machining Process ◽  
Processing Route ◽  
Optimal Route ◽  
Optimal Processing ◽  
Global Optimal ◽  
Level Method ◽  
Multi Level ◽  
Changing Times

In this paper, a multi-level method has been adopted to optimize the holes machining process with genetic algorithm (GA). Based on the analyzing of the features of the part with multi-holes, the local optimal processing route for the holes with the same processing feature is obtained with GA, then try to obtain the global optimal route with GA by considering the obtained local optimal route and the holes with different features. That is what the multi-level method means. The optimal route means the minimum moving length of the cutting tool and the minimum changing times of the cutting tool. The experiment is carried out to verify the algorithm and the proposed method, and result indicates that with GA and using the multi-level method the optimal holes machining route can be achieved efficiently.

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