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

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w D

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ct F

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• 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.