Influence of End Mill Geometry on Milling Force and Surface Integrity While Machining Low Rigidity Parts
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ORIGINAL CONTRIBUTION
Influence of End Mill Geometry on Milling Force and Surface Integrity While Machining Low Rigidity Parts Shrikrishna Nandkishor Joshi1
•
Gururaj Bolar2
Received: 11 May 2020 / Accepted: 13 August 2020 Ó The Author(s) 2020
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°. Keywords Thin-wall Helix angle Tool diameter Cutting flute Chatter Surface roughness
& Gururaj Bolar [email protected] 1
Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Guwahati 781 039, Assam, India
2
Department of Mechanical and Manufacturing Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education, Manipal 576 104, Karnataka, India
Introduction In the modern competitive world, manufacturing industries are continuously thriving for achieving higher productivity and product quality. Also, 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]. But 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, thus affecting the service life and performance. Therefore, the thin wall machining process has been analyzed by several researchers. Ratchev et al. [3] developed an analytical force model to predict the forces while machining straight thin-wall parts. The model integrated the perfect plastic layer model with a finite element model to predict the part deflection and, in turn, the machining forces. Houjun Qi [4] developed an elastic cutting model that took into account the wall deflection and changing workpiece curvature. The developed model predicted with accuracy the force values. Further, the analysis of process parameters revealed that feed per tooth was the primary factor affecting the cutting force. The cutting forces generated while m
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