Abstract
The study aims to understand the deformation mechanics that occurs during down and up milling of aluminium thin wall fabrication. With cutting forces as inputs, material properties were defined by the Coffin-Manson relation and the Smith-Watson-Topper model. Hysteresis was found in the process of machining aluminium thin walls. Furthermore, the pattern of cutter loads differentiated the up and down milling through hysteresis. The finite element method was followed using ANSYS v14.5 software in the fatigue workbench to analyse the aspect. Down milling introduced both deflection and deformation. Conversely, up milling did not exhibit deflection. However, the Bauschinger effect and distinct fracture surfaces were diagnosed during up milling. By exploring the nature of hysteresis and fracture surfaces, the selection of down and up milling was made.
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