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![Fig. 2: Overview display of MASTERCAM X MR2 software [3]](profile/Ts-Khairul-Akmal-Shamsuddin/publication/281079607/figure/fig9/AS:668642073137173@1536428101797/Overview-display-of-MASTERCAM-X-MR2-software-3_Q320.jpg)
![Fig. 8: Travel of the tool illustration [9]](profile/Ts-Khairul-Akmal-Shamsuddin/publication/281079607/figure/fig4/AS:284506587189266@1444843064929/Travel-of-the-tool-illustration-9_Q320.jpg)
This project presents a comparison of milling cutting path strategies for thin-walled aluminum alloys fabrication. To search for more efficient cutting path strategies for thin-walled parts, an interactive process planning and analyzing method is introduced. Several rigid combinations of machining parameters are examined based on the evaluation of...
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... are several setting need to be done in order to get the right process method for machining the product of thin-walled aluminum alloys. Mastercam X MR2 software was used in this project to select the milling cutting path strategies of each cutting process. The overview and modeling workpiece display using Mastercam X MR2 software are shown as Fig. 2 and 3.Other than that, the parameters also must be allocated to accomplish the condition of machining such as cutting speed, feed rate and depth of cut which is important in order to observe the correct parameters for the correct process. All the parameters are in a constant value of setting. Then, the experiments can be done accordingly to ...
Context 2
... thinner as the cutter tooth rotates. This process produces better surface finish and dimensional accuracy as be mentioned by R.K Rajput, Manufacturing Technology". The same as this strategy, had produced a better surface roughness with the average values of Ra are about 1.361 µm for wall A and 1.541 µm for wall B. Whereas by referring to the Fig. 12, the cutting strategies of Zigzag, Constant Overlap Spiral and Parallel Spiral Clean Corner have same types of pattern machining time without more less than 200 minutes. ...
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Citations
... Bu nedenle bazı araştırmacıların ince duvarlara sahip parçaların işlenmesinde istenen boyutsal doğruluk ve üstün yüzey kalitesine ulaşmaya odaklanarak kesme parametrelerinin optimizasyonu üzerine çalışmışlardır. Shamsuddin et al. (2013) çalışmalarında ince duvarlı alüminyum parçaların frezelenmesinde farklı işleme stratejilerinin bir karşılaştırmasına odaklanmıştır. Yüzey pürüzlülüğü, işleme süresi ve duvar kalınlığının doğruluğu ile ilgili sınırlamaların, ince duvarlı parçaların işlenmesinde yüksek verimlilik elde edilmesi açısından çok önemli olduğu sonucuna varmışlardır. ...
Bu çalışmada, kuru işleme koşullarında serbest formlu ince cidarlı AA 5083-H111 alaşımın kaplamasız karbür parmak freze ile işlenmesinde cidar kalınlığının, kesme hızının ve ilerleme miktarının yüzey pürüzlülüğü üzerindeki etkilerinin belirlenmesine odaklanmıştır. Ayrıca en düşük yüzey pürüzlülüğü için optimum kesme parametrelerinin belirlenmesinde Taguchi yöntemi ve regresyon analizi uygulanmıştır. Deney tasarımı Taguchi L32 (21x42) dizinine göre hazırlanmıştır. Deney ve analiz sonuçlarına göre, yüzey pürüzlülüğünü en aza indirmek için optimum kesme parametre seviyeleriA2B1C4 (5 mm cidar kalınlığı, 0,05 mm/diş ilerleme miktarı ve 200 m/dak) belirlenmiştir. ANOVA analiz sonucuna göre yüzey pürüzlülüğü üzerine en etkin kesme parametresi %57,14 ile ilerleme miktarı olduğu tespit edilmiştir. Yüzey pürüzlülüğü için yapılan regresyon analiz sonuçlarında ikinci derece regresyon analiz sonuçları lineer regresyon sonuçlarına göre gerçek değerlere en yakın sonuçları verdiği görülmüştür. özet 250 kelimeyi aşmamalı ve paragraf kullanılmamalıdır.
... The main drawbacks associated to the fabrication of thin monolithic panels by milling are the final surface roughness, the overall machining time and the big waste of material, which can account for more than 95% of the initial billet. 3 Still, this type of panels is commonly used in aeronautics. 4 Roll forming allows overcoming some of the disadvantages of milling, but its use is limited to large batch production of thin monolithic panels having a uniform profile throughout the surface (e.g. the motorway metallic rails). ...
This paper investigates the applicability of single point incremental forming to fabricate stiffening grooves in thin metallic panels. The work combines experimentation, finite element and analytical modelling to determine the required forces and the maximum allowable groove depths that can be produced without tearing. The analytical modelling is based on a framework that was previously developed by the authors and combines in-plane membrane stretching and fracture forming limits. Comparison of the results obtained by the analytical framework against experimental and finite element data proves its effectiveness to replicate the deformation mechanics of groove stiffening by single point incremental forming. Results also prove that groove stiffening by single point incremental forming is an easy and effective alternative to conventional reinforcement of thin metallic panels by welding or fastening of stringers.
... To control the milling deformation of flexible components, the development of other methods and techniques have been achieved. These include milling path planning [35], [36], online compensation [37], electromagnetic induction [38], damping method [31], [39], [40], fixtures [41], [42], [43], [44], a waterfall machining technique developed by Boeing Manufacturing R&D group [45] and a sacrificial structures method [46]. ...
Thin-walled parts are commonly used in the aerospace sector. However, there are serious machining challenges, such as deflection, deformation and vibration. The final thin-walled component machining will deteriorate the dimensional accuracy and surface quality. This is due to the vibration and deformation that occurs during flexible milling of thin-walled structures since the workpiece rigidity is lower than the cutting forces of the milling cutter. The gradual reduction of the thin-wall thickness during the end milling process results in significant deflections and deformations due to its low rigidity and low stiffness. In recent years, different approaches have been used to deal with these challenges. This paper presents a new technique for machining thin-walled parts with great accuracy, excellent flatness and straightness properties, and good productivity. The authors have developed a new milling technique using simultaneous double-sided cutter milling, in which synchronized vertical double end milling cutter finishes and machines both thin-wall surfaces simultaneously. This produces lower cutting thrust forces on the walls, as each cutting thrust force cancels out the other. The rotation of the milling machine spindle is transmitted to the double cutters by an in-house double-axis adapter. Surface errors are minimized, flatness and straightness properties are significantly improved, and the thin-wall deflection can be neglected, as shown in our results. The thin wall can be finished in only one pass, and a 50% reduction in machining time can be achieved. In addition, thin-wall flatness is improved about two to three times, compared to the conventional milling procedure.
... Monolithic panels produced by milling are homogeneous, offer excellent strength-toweight ratios and provide significant cost savings in assembly, labor and tooling. However, their application is limited by surface roughness, machining time, geometry accuracy and material wastage (typically, above 95% of the initial blank) [3,4]. These panels are mainly used in aerospace applications. ...
This paper is focused on the hybridization of additive manufacturing with single-point incremental forming to produce stiffening grooves in thin metal parts. An analytical model built upon in-plane stretching of a membrane is provided to determine the tool force as a function of the required groove depth and to estimate the maximum allowable groove depth that can be formed without tearing. The results for additively deposited stainless-steel sheets show that the proposed analytical model can replicate incremental plastic deformation of the stiffening grooves in good agreement with experimental observations and measurements. Anisotropy and lower formability caused by the dendritic-based microstructure of the additively deposited stainless-steel sheets justifies the reason why the maximum allowable depth of the stiffening grooves is approximately 27% smaller than that obtained for the wrought commercial sheets of the same material that are used for comparison purposes.
... This is related to the tendency to minimize the mass of manufactured parts. The technological difficulties associated, among others, with machining of thin-walled elements are very important issues both from a scientific and practical point of view [11,26]. One of the main problems is the formation of undesirable deformations of thin-walled elements after machining and removal of the forces clamping the workpiece in the clamping device [27]. ...
The paper presents an evaluation of post-machining deformations of thin-walled elements as regards the mechanical properties of the applied, rolled semi-finished products. Nowadays, wrought aluminum alloys, supplied primarily in the form of rolled plates, are widely applied in the production of thin-walled integral parts. Considering the high requirements for materials, especially in the aviation sector, it is important to be aware of their mechanical properties and for semi-finished products delivered after plastic working to take into account the so-called “technological history” concerning, inter alia, the direction of rolling. The study focused on determining the influence of the ratio of the tension direction to the rolling direction on the selected mechanical properties of the EN AW-2024 T351 aluminum alloy depending on the sample thickness and its relation to the deformation of thin-walled parts. Based on the obtained results, it was found that the sample thickness and the ratio of the tension direction to the rolling direction affected the mechanical properties of the selected aluminum alloy, which in turn translated into post-machining deformations. Summarizing, the textured surface layer had a significant impact on the mentioned deformation. Greater deformations were noted for samples made of a semi-finished product with a thickness of 5 mm in comparison to 12 mm. It was the result of the influence of the surface layer, which at lower thickness had a higher percentage of contents than in thicker samples.
... Its thickness is smaller at the base and increases towards the upper edge of the wall. The value of the elastic deformation during machining depends on the mechanical properties of the materials being machined, i.e., in the considered case, the various aluminum alloys [4][5][6][7]. Figure 1 shows the deformation of a thin wall under the influence of the cutting force during machining. Thin-walled elements are particularly susceptible to post-machining deformations, occurring mainly after the finished machining process. ...
In modern constructions, especially aircraft, the aim is to minimize the weight of the components used. This necessitates the use of innovative construction materials, or the production of these parts with ever-decreasing wall thicknesses. To simplify assembly and improve strength properties, so-called structural elements are being used in the form of monolithic elements, which are replacing the assemblies of parts joined by, for example, riveting. These structures often have a complex, thin-walled geometry with deep pockets. This paper attempts to assess the accuracy of manufacturing thin-walled elements, in the shape of walls with different geometries, made of various aluminum alloys. Machining tests were conducted at different cutting speeds, which allowed comparisons of the geometric accuracy of parts manufactured under conventional and high-speed cutting conditions. Based on the result obtained, it was found that the elements made of EN AW-7075 T651 alloy underwent the greatest deformations during machining in comparison to that of other two materials (EN AW-6082 T651 and EN AC-43000). An increase in the geometrical accuracy of the manufactured elements was also observed with the increase in the cutting speed for the HSC range. Hence, to minimize the postmachining deformation of thin-walled elements, the use of high-speed cutting is justified.
... The authors concluded that a combined approach i.e., concave and convex machining with four fluted carbide end mill produced superior quality and precise thin-wall components. Shamsuddin et al. [27] compared milling cutting path strategies on surface finish, thickness accuracy, and machining time for thin-walled aluminum alloys. MasterCam X MR2 software was used to obtain the best tool path strategy. ...
Thin-walled parts made of aluminum alloy are mostly used as structural elements in the aerospace, automobile, and military industries due to good homogeneity, corrosion resistance, and the excellent ratio between mechanical properties and mass. Manufacturing of these parts is mainly performed by removing a large volume of material, so it is necessary to choose quality machining parameters that will achieve high productivity and satisfactory quality and accuracy of machining. Using the Taguchi methodology, an experimental plan is created and realized. Based on its results and comparative analysis of multi-criteria decision making (MCDM) methods, optimal levels of machining parameters in high-speed milling of thin-walled parts made of aluminum alloy Al7075 are selected. The varying input parameters are wall thickness, cutting parameters, and tool path strategies. The output parameters are productivity, surface quality, dimensional accuracy, the accuracy of forms and surface position, representing the optimization criteria. Selection of the optimal machining parameter levels and their ranking is realized using 14 MCDM methods. Afterward, the obtained results are compared using correlation analysis. At the output, integrative decisions were made on selecting the optimal level and rank of alternative levels of machining parameters.
... Increasingly frequently, the term "integral (structural) thin-walled elements" is used. Their characteristics comprise a uniform design, relatively high rigidity and low weight in comparison to their overall dimensions and a high strength to empty weight ratio [1, 4,5]. ...
... They are very often produced using monolithic plates made of light metal alloys (aluminium, titanium) [7]. In high-performance milling of such elements, chips amount to as much as 95% of the semi-finished product weight [4,5,[8][9][10][11][12][13]. ...
The paper examines the impact of selected machining techniques and the semi-finished product technological history on deformations of thin-walled elements made of EN AW-2024 T351 aluminium alloy after milling. The following techniques have been implemented: High Performance Cutting, High Speed Cutting, conventional finishing (CF) and combinations of these techniques. As for the semi-finished product technological history, the rolling direction has been analysed. It has been assumed that it can be relevant in relation to the cutting tool feed direction and, in consequence, exert considerable impact on the stress, as well as deformation following machining. The interest in this issue proceeds from significant challenges faced by the industry, particularly in the aerospace sector. The analysis of results obtained has shown that milling in the direction perpendicular to the rolling direction results in larger deformations than milling in the parallel direction. Additionally, it has been revealed that applying a correctly selected machining technique makes it possible to minimise post-machining deformations of thin-walled elements.
... Machining Setting and Programming (MASTERCAM X MR2) based on cutting strategies before running the CNC end milling machine, there are various setting need to be competed in order to get the correct process method for machining the product of workpiece. Mastercam X MR2 software was used to select the milling cutting path strategies of each cutting process [9]. All the parameters are in a constant value of setting. ...
This paper discusses the effect of tool path strategies and pocket geometry to surface roughness due to pocket milling process. The machining processes have been performed on mould steel DF2 using carbide insert end mill as the cutting tool. The cutting parameters for this experiment were kept constant while the variables were cutting tool, path strategies and pocket geometries at three levels each. The effectiveness of different tool path strategy and different pocket geometry is evaluated in terms of measured surface roughness (Ra) of the workpiece. The grade of a pocket is directly proportional with its surface roughness. The lowest surface roughness measurement was produced by pocket geometry B with parallel spiral cutting tool path strategy.
... Therefore, the total consumed energy can be the right index for finding the optimum cutting path strategies. Some cutting path studies have been conducted on a range of metals such as 1000 series aluminium alloy, aluminium 5083 alloy, AISI P20 steel and stainless steel to evaluate machining outputs such as machining time and surface roughness without considering the energy consumption as one of the important factors in the mass production [1][2][3][4]. ...
... Apart from convexly curved shape studies, a study conducted on a similar theme, involving cutting path strategies but on fabricating thin-walled aluminium alloy [2]. This study suggested that parallel spiral strategy produced the best surface finish compared to zig-zag, constant overlap spiral, parallel spiral clean corners, high speed, one way and true spiral. ...
The use of aluminium in automotive and aerospace parts as well as low-pressure moulds are widely popular in the manufacturing industry. The good machinability of its alloy is one of the many reasons why aluminium is a default choice. In this study, aluminium 6061 alloy was chosen. However, studies were done on the cutting path strategies in machining especially for convex curved shape and their effects on the surface finish of the workpiece were not very informative. Five cutting strategies were involved and compared – parallel, morphed spiral, spiral, radial and circle. As industries are moving towards minimising the carbon footprint of their manufacturing processes, this study provided a good opportunity to include the investigation of the energy consumption of the cutting path strategy as well. Essentially, this study was aimed to investigate the effect of cutting path strategies on the workpiece’s surface roughness, and the energy consumption of the machining process as well as to establish the optimum cutting parameters for the best cutting path strategy. Overall, the parallel cutting path strategy was found to be the most suitable cutting strategy to be used for convexly curved surface machining.
