Development Of Cutter Geometrical Feature For Machining Thin Wall Part

• Main Author: Tajry, Mohd Zulhairi
• Format: Thesis
• Language: English
• Published: UTeM 2017
• Subjects: T Technology (General); TJ Mechanical engineering and machinery
• Online Access: http://eprints.utem.edu.my/id/eprint/23452/; https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=112954; TJ211.42.L64 2017

Demand for cost-effective aircrafts fabrication has motivated the aerospace industry to use nontraditional materials and new aircraft structural design. New aircrafts are designed with monolithic component to replace large number of assembled component. For manufacturers, high-performance cutting tool is essential as more than 80% of the material is removed to produce the monolithic component. Most of the monolithic components have thin-wall feature with low stiffness and deformation is more likely to occur in its machining process, resulting in dimensional surface errors. Most of the existing research on machining thin-wall component merely focused on the process planning and there was no scientific study on the effects of cutter geometric feature on component failure. Tool geometry has a direct influence on the cutting performance and should be taken into consideration. In this research, due to the importance of machining efficiency, development of new cutter design specifically for machining thin-wall components are studied. This study consists of both experimental and statistic techniques to evaluate the machining performance associated with the cutter geometry for different types of end mill, namely variable helix constant pitch (VHCP), variable helix variable pitch (VHVP) and tabular helix constant pitch (THCP). Based on the established relationship between cutter geometry feature and machining performances, the optimal cutter geometry is determined by using the non-parametric statistical ranking technique. From the experimental results, tool TD3 with 31o/33o/35o helix angle and equal pitch angle of 90o between teeth (THCP) is the most suitable design to be used for machining thin-wall workpiece. In addition, it shows that careful design of the pitch and helix angle combination can increase the machining performances of thin-wall part. The outcome from this research has potential benefits in providing new scientific knowledge on the selection of effective cutter geometry for machining low rigidity components.