Abstract
High 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°.
Highlights
In the modern competitive world, manufacturing industries are continuously thriving for achieving higher productivity and product quality
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°
The high force value at a low helix angle is related to the work-tool engagement
Summary
In the modern competitive world, manufacturing industries are continuously thriving for achieving higher productivity and product quality. The trades are striving to produce components in a reasonable time and at lower costs. Components having thin sections are extensively used in aerospace, automobiles, electronic component, and moldmaking industries [1, 2]. In the machining of thin-wall structures, the cutter enters and exits the material in an interrupted manner leading to the dynamic deflection of the low rigidity parts. The deflection of thin-wall components leads to poor surface finish and dimensional accuracy, affecting the service life and performance. The thin wall machining process has been analyzed by several researchers
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