Development Of Simultaneous Twin Cutter For Machining Thin-Wall Component

• Main Author: Mohamad Azmi, Helmi Affendi
• Format: Thesis
• Language: English; English
• Published: 2019
• Subjects: TJ Mechanical engineering and machinery
• Online Access: http://eprints.utem.edu.my/id/eprint/24701/; https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=116952

Peripheral milling of very flexible components with a large span ratio of heights to thickness such as monolithic component is a common manufacturing process in the aerospace industries. In such cases, the wall thickness of the part is further reduced, leading to dimensional surface error that causes the finished part to be out of specification. The surface errors are mainly induced by the acts of cutting force, which deflect the wall on the opposite direction. To solve the problem, this research proposes a simultaneous twin cutter machining technique aim to control the wall deflection. A twin cutter adaptor consists a set of gear arrangement design for transmitting the rotation of the machine spindle has been developed. A set of experimental work performs to validate the effectiveness of the propose technique. The research focuses on machining thin-wall part made of Aluminium Alloy 7075-T6 as materials. Totals 6 runs of constant speed of 1500 rpm consisting of 50, 80 and 200 mm/min feed rate for both single and twin cutter respectively were used. The experimental results indicated that, the deflection of the thin-wall part can be neglected and hence minimize the surface errors since the same cutting force appears on both sides of the wall surface. The proposed technique can increase the component accuracy and reduce the machining time up to 50 percent as only one pass is required to mill the wall structure compare with the single cutter machining technique.