Effects of Helix Angle on Cutting Performance for Machining Thin-Wall Aerospace Monolithic Component

Abstract

The thin-walled component is mostly used in the aerospace industry. During machining the thin-walled components, deflection of wall occurs and causes the surface dimensional error. This paper focuses on the effect of end mill helix angle on the surface dimensional error and surface roughness when machining thin wall structure. End mills uncoated carbide were fabricated with a difference helix angle which are 25°, 30°, 35°, 40° and 45°. The results show, helix angle 35° produce smaller surface dimensional error and smoothest followed by 40°, 45°, 30° and 25°. The smaller helix angle provided high cutting force that causes more surface dimensional error due to chatter and reduction of contact time when then end mill engage with the workpiece material. Results from this research help to guide the machinist to machine thin-wall component with the right cutting tool.

Cutting Technology Innovation in Production of Porous Cellular Mat

“…It consist of a motor, the pulleys, a blade and the customized frames that were built and assembled together. Basically, the concept to design a cutting system for a hollow structure shape was based on the material removal mechanism, where the primary tool engages a workpiece to remove a layer of material in the form of a chip [5]. As the primary blade engages to the product, the material ahead of the blade is sheared and deformed under an enormous pressure.…”