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Evaluation of Thin Wall Milling Ability Using Disc Cutters.

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Summary

Manufacturing thin metal walls by milling can cause bending due to residual stress. Wall height significantly impacts this deformation, followed by feed rate and width, according to an empirical model.

Keywords:
aluminum alloybendingdisc cutterempirical mathematical modelinfluence factorsmachining deviationmillingresidual stressthin wall

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Area of Science:

  • Manufacturing Engineering
  • Materials Science
  • Mechanical Engineering

Background:

  • Industrial production often requires manufacturing thin walls (<1mm) from metal workpieces.
  • Milling with disc cutters is a common method for producing these thin-walled parts.
  • This process can induce residual stresses, leading to form deviations like bending in thin walls.

Purpose of the Study:

  • To evaluate material suitability for thin wall manufacturing via milling.
  • To identify factors influencing residual deformation and form deviation.
  • To develop an empirical mathematical model for predicting these deviations.

Main Methods:

  • Designed a test sample and experimental research program.
  • Utilized disc cutter milling on an aluminum alloy workpiece.
  • Developed a power-type empirical mathematical model to quantify factor influence.

Main Results:

  • Identified key input factors: cutting speed, feed rate, cutter thickness, wall thickness, wall length, and height.
  • Quantified the influence of each factor on form deviation using model exponents.
  • Determined that wall height has the strongest influence (exponent 0.782), followed by feed rate (0.319) and wall width (0.169).

Conclusions:

  • Wall height is the most critical factor affecting residual deformation in thin walls produced by milling.
  • The empirical model provides insights into optimizing milling parameters to minimize form deviation.
  • Understanding these factors is crucial for producing dimensionally accurate thin metal parts.