Surface roughness analysis of five-axis flank milling strategies for slanted thin-walled pocketing: aerospace part

• Main Authors: Sundi, Syahrul Azwan, Izamshah, Raja, Kasim, Mohd Shahir, Othman, Intan Sharhida, Raffay, Mohamad Razly
• Format: Conference or Workshop Item
• Language: English
• Published: 2023
• Online Access: http://eprints.utem.edu.my/id/eprint/27872/1/Surface%20roughness%20analysis%20of%20five-axis%20flank%20milling%20strategies%20for%20slanted%20thin-walled%20pocketing%20aerospace%20part.pdf; http://eprints.utem.edu.my/id/eprint/27872/; https://link.springer.com/chapter/10.1007/978-981-19-1457-7_65

This research was initiated to investigate the effect of surface rough- ness when machining slanted thin-walled pocketing profiles with various flank milling machining strategies. In this research, Multi-Axis Flank Contouring strate- gies namely Combin Parelm and Combin Tanto were the main machining strategies to machine an actual chosen aero-structural sample with slanted thin-walled of 105o and 85o. Samples of physical machining were obtained from a five-axis CNC milling machine DMU 60 Monoblock with Siemens 840D controller. The material used was aluminum AA6063 and the cutting tools were carbide K10 material of two flutes end mill with diameter 12 and 6 mm uncoated. At the end of this study, an analysis with regard to the surface finish was performed utilizing Mitutoyo surface rough- ness tester to measure the surface roughness of the machined part specimens. Three different sections namely approach, middle, and leaving area of the slanted thin- walled were taken for further analysis. In addition, the arithmetical roughness (Ra) value is used to measure the overall surface finish quality. The Combin Tanto strategy resulted better surface quality in comparison to the Combin Parelm strategy due the overwritten of depth of cut which occurred during the machining process although was set constantly. The tool trajectory and tilting position were believed to be the main factors affecting the surface finish of the machined part. The orientation of the cutting tool affected all the three areas evaluated and lead to an uneven depth of cut amount during the machining process.