Title: Distinguishing process - impact of down milling and up milling in machining aluminium thin wall

Authors: L. Gopinath; S. Jerome; Balamurugan Gopalsamy

Addresses: RN – Civil Aircraft Centre (C-CADD), CSIR – National Aerospace Laboratories, Bangalore 560017, India; Department of Metallurgical and Materials Engineering, National Institute of Technology, Tiruchirappalli 620015, India ' Department of Metallurgical and Materials Engineering, National Institute of Technology, Tiruchirappalli 620015, India ' Structural Technologies Division, CSIR – National Aerospace Laboratories, Bangalore 560017, India

Abstract: The study aims to understand the deformation mechanics that occurs during down and up milling of aluminium thin wall fabrication. With cutting forces as inputs, material properties were defined by the Coffin-Manson relation and the Smith-Watson-Topper model. Hysteresis was found in the process of machining aluminium thin walls. Furthermore, the pattern of cutter loads differentiated the up and down milling through hysteresis. The finite element method was followed using ANSYS v14.5 software in the fatigue workbench to analyse the aspect. Down milling introduced both deflection and deformation. Conversely, up milling did not exhibit deflection. However, the Bauschinger effect and distinct fracture surfaces were diagnosed during up milling. By exploring the nature of hysteresis and fracture surfaces, the selection of down and up milling was made.

Keywords: thin wall milling; hysteresis; deformation; up milling; down milling; Bauschinger effect.

DOI: 10.1504/IJMPT.2022.120658

International Journal of Materials and Product Technology, 2022 Vol.64 No.2, pp.156 - 174

Received: 14 Jul 2020
Accepted: 05 Aug 2021

Published online: 31 Jan 2022 *

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