Development Of Simultaneous Twin Cutter For Machining Thin-Wall Component

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 cause...

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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/24701/1/Development%20Of%20Simultaneous%20Twin%20Cutter%20For%20Machining%20Thin-Wall%20Component.pdf http://eprints.utem.edu.my/id/eprint/24701/2/Development%20Of%20Simultaneous%20Twin%20Cutter%20For%20Machining%20Thin-Wall%20Component.pdf
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id	my-utem-ep.24701
record_format	uketd_dc
institution	Universiti Teknikal Malaysia Melaka
collection	UTeM Repository
language	English English
advisor	Raja Abdullah, Raja Izamshah
topic	TJ Mechanical engineering and machinery
spellingShingle	TJ Mechanical engineering and machinery Mohamad Azmi, Helmi Affendi Development Of Simultaneous Twin Cutter For Machining Thin-Wall Component
description	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.
format	Thesis
qualification_name	Master of Philosophy (M.Phil.)
qualification_level	Master's degree
author	Mohamad Azmi, Helmi Affendi
author_facet	Mohamad Azmi, Helmi Affendi
author_sort	Mohamad Azmi, Helmi Affendi
title	Development Of Simultaneous Twin Cutter For Machining Thin-Wall Component
title_short	Development Of Simultaneous Twin Cutter For Machining Thin-Wall Component
title_full	Development Of Simultaneous Twin Cutter For Machining Thin-Wall Component
title_fullStr	Development Of Simultaneous Twin Cutter For Machining Thin-Wall Component
title_full_unstemmed	Development Of Simultaneous Twin Cutter For Machining Thin-Wall Component
title_sort	development of simultaneous twin cutter for machining thin-wall component
granting_institution	Universiti Teknikal Malaysia Melaka
granting_department	Faculty of Manufacturing Engineering
publishDate	2019
url	http://eprints.utem.edu.my/id/eprint/24701/1/Development%20Of%20Simultaneous%20Twin%20Cutter%20For%20Machining%20Thin-Wall%20Component.pdf http://eprints.utem.edu.my/id/eprint/24701/2/Development%20Of%20Simultaneous%20Twin%20Cutter%20For%20Machining%20Thin-Wall%20Component.pdf
_version_	1747834092151373824
spelling	my-utem-ep.247012021-10-05T12:03:04Z Development Of Simultaneous Twin Cutter For Machining Thin-Wall Component 2019 Mohamad Azmi, Helmi Affendi TJ Mechanical engineering and machinery 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. 2019 Thesis http://eprints.utem.edu.my/id/eprint/24701/ http://eprints.utem.edu.my/id/eprint/24701/1/Development%20Of%20Simultaneous%20Twin%20Cutter%20For%20Machining%20Thin-Wall%20Component.pdf text en public http://eprints.utem.edu.my/id/eprint/24701/2/Development%20Of%20Simultaneous%20Twin%20Cutter%20For%20Machining%20Thin-Wall%20Component.pdf text en validuser https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=116952 mphil masters Universiti Teknikal Malaysia Melaka Faculty of Manufacturing Engineering Raja Abdullah, Raja Izamshah 1. Ahn, K.G., Min, B.K. and Pasek, Z.J., 2006. Modeling and compensation of geometric errors in simultaneous cutting using a multi-spindle machine tool. 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Development Of Simultaneous Twin Cutter For Machining Thin-Wall Component

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