Investigations into the influence of tool helix angle during end milling of open straight and curved thin-wall parts

Bolar, Gururaj and Joshi, Shrikrishna (2020) Investigations into the influence of tool helix angle during end milling of open straight and curved thin-wall parts. International. Journal of. Machining and Machinability of Materials, 22 (3/4). pp. 212-232. ISSN 1748-5711

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Abstract

In this paper, the influence of cutting tool helix angle on performance parameters viz., milling force, part deflection, surface finish, chip morphology and micro-hardness considering open straight and curvilinear thin-walled parts is analysed. It was found that end mills with helix angle of 45º and 55º helped in achieving good surface finish and form accuracy while machining thin-wall parts. During machining, parts having concave geometry due to its inherent rigidity, generated higher milling force. But the wall deflection and form error was relatively lower in comparison with the straight wall thereby resulting in better surface finish. Also, formation of built-up-edge (BUE) at the cutting edge of end mills having 35° helix was noted which aided in surface defects. Back surface of the chips machined using 35º tools showed prominent lamella like structures but tools having higher helix angles were found to produce relatively lamella free surface.

Item Type: Article
Uncontrolled Keywords: thin-wall; helix angle; chip morphology; micro hardness; milling force; surface roughness; built-up-edge; BUE; finite element simulation
Subjects: Engineering > MIT Manipal > Mechanical and Manufacturing
Depositing User: MIT Library
Date Deposited: 16 Jul 2020 09:45
Last Modified: 16 Jul 2020 09:45
URI: http://eprints.manipal.edu/id/eprint/155441

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