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TABLE OF CONTENT
Abstrak i
Abstract ii
Acknowledgement iii
Table of Content iv
List of Tables viii
List of Figures ix
List Abbreviations, Symbols and Nomenclatures xi
CHAPTER 1: INTRODUCTION 1
1.1 Research Background
1 1.2
Problem Statement Current Technique in Machining Thin-Wall 3
1.3 Objectives
4 1.4
Scope of Project 5
CHAPTER 2: LITERATURE REVIEW
6 2.1
Introduction 6
2.2 Thin Wall Machining
6 2.2.1
Shoulder Milling 7
2.2.2 Milling Thin-Walls
8 2.2.3
Milling Thin Bases 10
2.2.4 Cutting Medium
11 2.2.5
Thin-Wall Workpiece Material 12
2.3 Cutting Tool
13 2.3.1
End Mill 13
2.3.1.1 Two-Flute End Mills
13 2.3.1.2
Three-Flute End Mills 14
2.3.1.3 Multiple-Flute End Mills
15
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2.3.2 End Mill Geometrical Feature
15 2.3.3
Importance of Helix Angle on End Mill Geometrical Feature 16
2.3.4 Cutting Tool Material
17 2.4
Finite Element Analysis 18
2.4.1 Modeling, Simulation and Prediction
19 2.4.2
Deflection When Machining Thin-Wall Part 20
2.4.3 Modelling On DEFORM-3D
21
CHAPTER 3: METHODOLOGY 22
3.1 Introduction
22 3.2
Research Flow Chart 22
3.3 Cutter Geometrical Feature
25 3.4
Thin-Wall Component 25
3.5 Design of Experiment DOE
26 3.6
Part Modeling 27
3.7 Finite Element Analysis FEA
28 3.7.1
Mesh Types 29
3.7.2 Mesh Size 29
3.7.3 Boundary Conditions
31 3.7.4
Contact Conditions 32
3.7.5 Other Finite Element Condition
33 3.7.6
Simulations 34
3.8 Experimental Setup
34
CHAPTER 4: RESULTS AND DISCUSSIONS 37
4.1 Introduction
37 4.2
Surface Error 38
4.2.1 Run 1 2 flute 45° helix angle of end mill with 2.5 mm wall thickness and 25
mm wall height of thin-wall 39
4.2.2 Run 2 3 flute 45° helix angle of end mill with 1.5 mm wall thickness and 30
mm wall height of thin-wall 40
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4.2.3 Run 3 3 flute 35° helix angle of end mill with 2.5 mm wall thickness and 35 mm wall height of thin-wall
40 4.2.4 Run 4 4 flute 25° helix angle of end mill with 2.5 mm wall thickness and 30 mm
wall height of thin-wall 41
4.2.5 Run 5 4 flute 35° helix angle of end mill with 1.5 mm wall thickness and 25 mm wall height of thin-wall
42 4.2.6
Run 6 2 flute 35° helix angle of end mill with 2 mm wall thickness and 30 mm wall height of thin-wall
43 4.2.7 Run 7 2 flute 25° helix angle of end mill with 1.5 mm wall thickness and 35 mm
wall height of thin-wall 43
4.2.8 Run 8 3 flute 25° helix angle of end mill with 2mm wall thickness and 25mm wall height of thin-wall
44 4.3
Simulation Validation 44
4.3.1 Simulation Predicted Surface Error
46 4.3.2 Experiment Surface Error
47 4.3.3 Surface Error Comparison
48 4.4
Statistical Analysis of Experimental Data 52
4.4.1 Statistical Design Matrix
52 4.4.2
Statistical Output Analysis 53
4.4.2.1 ANOVA Output
53 4.4.2.2 Residual Analysis
54 4.4.2.3 Response Surface
56 4.4.3
Optimization and Validation 56
CHAPTER 5: CONCLUSION AND RECOMMENDATION 60
