Influence of tool parameters on machining distortion of thin wall thin floor components

Abstract

Distortion or warpage is one of the most common problems encountered during machining of thin wall thin floor parts. Material up to 90% are removed on computer numerical control (CNC) machines, leading to part distortion due to action of cutting forces, temperature, and clamping forces. Selection of right kind of tool and cutting parameters are important to control distortion as they influence cutting forces and temperature. In this study, multi-level full factorial machining experiments were conducted with three varying tool parameters viz., number of flutes, direction and angle of helix at constant cutting conditions to understand the effect of these on machining distortion. Cutting forces and temperature generated during machining with these different tool parameters were also studied by simulation experiments using finite element software DEFORM 3D. Results show a significant effect of these tool parameters on distortion.

Keywords:

• Machining distortion
• thin wall thin floor parts
• helix direction
• helix angle
• number of flutes

Acknowledgement

The authors are thankful to the Head of Department, Osmania University for his constant encouragement and Support for conducting experiments. The authors are also very thankful to all those who helped in carrying out the experiments.