Accuracy of machined component is one of the challenging tasks for manufacturer. In the aerospace industry, machining process is widely used for fabrication of unitized-monolithic component that contains a thin-walled structure. During machining, the cutting forces cause deflection to the thin-wall section, leading to dimensional form errors that cause the finished part to be out of specification or failure. Most of the existing research for machining thin-wall component only concentrated on the process planning and the effects of cutter geometric feature is often neglected. Tool geometric feature has a direct influence on the cutting performance and should not be neglected in the machining consideration. This paper reports on the effect of helix angle on the magnitude of wall deflection. The established effects will be used for the development of high performance cutting tool for specifically machining thin-wall component.

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The effect of maleated polypropylene (MAPP) as binder on the mechanical properties of kenaf fibre/polypropylene (KF/PP) composites is studied. Ratios between kenaf fibre and PP having 10:90, 30:70 and 50:50 in weight ratio were selected. Further, MAPP having 1, 3 and 5 percent in percentage of weight ratio was mixed in KF/PP composites. Hot press machine was used to produce tensile test samples of KF/PP composites. The mechanical properties that are tensile strength, tensile modulus and elongation at break of KF-PP composites were obtained from tensile test result. It is found that the tensile strength and tensile modulus increase with increasing the kenaf fibre loading and higher percentage of MAPP. Further, the elongation at break for KF/PP composites shows lower result when increasing of kenaf fibre loading. However, when percentage of MAPP added in KF/PP composites increases, the elongation at break increased slightly. Thus, result shows that kenaf fibre/PP composites with binder were better in tensile strength, tensile modulus however the elongation at break shows weak result unless the binder was added.

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