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A NOVEL TWIN SPINDLE MILLING CUTTER STRATEGY FOR
EFFECTIVELY MACHINING THIN-WALL AEROSPACE STRUCTURAL
COMPONENT
EXAMINER:
ENGR. DR. MOHD HADZLEY BIN ABU BAKAR
(FACULTY OF MANUFACTURING ENGINEERING)
• Research Background
• Problem Statement
• Objective• Objective
• Scope of Project
• Literature Review
• Methodology
• Expected Outcomes
Function:
Replace the large
number of assembled
component by
designing with one
Application:
Aircraft
industry
Thin-Walldesigning with one
piece flow of
monolithic
component
industry
The surface error is induced mainly
by the act of cutting forces, which
deflect the wall on the opposite
direction.
To solve the problem with current
technique, this project proposes a
twin spindle milling cutter
adapter to control the wall adapter to control the wall
deflection.
By employing this technique, the
milling force can be control and
hence minimize the wall
deflection which is the main
factor for the errors. Once the
wall deflection can be control the
part accuracy can be increase.
•To study the effect of
heat treatment and
thermal cycling on
mechanical properties
of mild steel.
The poor stiffness of
thin-wall feature
makes deformation is
more likely to occur
which resulting a
dimensional surface
error.
It is very difficult to
machine the side
surface of a thin-wall
workpiece with
precision
of mild steel.
Current cutting conditions under
low feed and small depth of cut
are used in order to control
machining accuracy. But it is
impossible to avoid low
productivity in this case.
To test and validate the
effectiveness of the new
developed twin spindle
milling cutter adapter on
machining thin wall low
rigidity component. rigidity component.
To design a twin
spindle milling
cutter adapter for
specifically
machining thin wall
low rigidity
component.
• In current industry practice, to machine a thin-wall component usually involve one or more of the following techniques:
(i) a lengthy and expensive trial and error numerical control validation process.
(ii) using a step machining approach, which alternately
milling each side of the wall.
• Distinctly all of these existing techniques on machining thin-wall feature have a tendency to lower productivity and difficulty in ensuring the component accuracy.
Step Machining
Approach
Finite Element
Analysis
Pro
ject
Flo
w D
iagra
mP
roje
ct F
low
Dia
gra
m
• Under this method, are expected that the deflection of the thin wall workpiece due to the cutting force can be neglected because the same cutting force appears on the both sides of the wall surfaces. wall surfaces.
• Side surface of a thin-wall workpiece are able to be machined with high accuracy, ensuring the same time high productivity.
• This research can lead to the discovery of new fundamental theory and concept on the part failure.