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
Scope of Project
Literature Review
Methodology
Expected Outcomes

Function:
Application:
Thin-Wall

Aircraft
industry

Replace the large

number of assembled
component by
designing with one
piece flow of
monolithic
component

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
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.

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
To studythe
theside
effect of
surface
of a thin-wall
heat treatment
and
workpiece
withon
thermal
cycling
precision
mechanical
properties
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.
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

Project Flow Diagram

 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.
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.