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CSME 2022/12
Volume 43 No.6
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549-558
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Effect of Serrated Endmill Geometry on Machining Responses of Al 2024 Thin-Walled Components
Darshan Sa, Shivaraj BWa, Bharatish Aa, Krishna Ma and Narasimha Murthy HNa
aDepartment of Mechanical Engineering, RV College of Engineering, Bengaluru, 560059, India
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Abstract:
Thin-walled components are widely adopted in aircraft structures due to the eminent characteristics such as light weight, high strength to weight ratio, high usability and ergonomics. However, the lower stiffness of these components results in static and dynamic instabilities during their machining. Thus, there is a requirement to reduce the deflection, stresses and unwanted vibrations during machining of thin-walled components. Adoption of serrated end mill can cause non-uniform distribution of chip thickness, reduction of effective axial depth of cut and cutting forces and improvement of chatter stability. This paper focuses on investigating the effect of serrated end mill geomet-rical parameters such as the number of flutes (2, 3, and 4), helix angle (30o, 35o, and 45o) and serration geom-etry (sinusoidal, median, and interrupted) on machin-ing responses of thin-walled components. The deflec-tions and stresses were computed using ANSYS explicit dynamics module. The thin wall deflection was mainly influenced by number of flutes and stresses by helix angle. The machining responses could be simultaneously minimized when maximum number of flutes, intermediate helix angle and median serration geometry were adopted.
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Keywords: Serrated End mills, Thin wall Deflection, Helix angle, Machining, Al 2024
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©
2022
CSME , ISSN 0257-9731
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