Influence of End Mill Geometry on Milling Force and Surface Integrity While Machining Low Rigidity Parts

Abstract

High precision and superior surface finish are of prime importance in thin-wall components used in the aerospace and automobile industries. In this paper, end milling experiments on aluminum alloy 2024-T351 were carried out to study the influence of end mill geometry on milling force and surface integrity of the machined parts. Machining using a 16-mm-diameter tool having a helix angle of 35° produced high force value and also generated chatter marks on the machined work surface. Furthermore, an inspection of the cutting tool indicated built-up-edge formation while machining with a 35° helix tool. Besides, surface damage in the form of surface tear was observed. Evaluation of microhardness revealed an increased value near to the machined surface in the case of two fluted 35° helix tool due to strain hardening. The results showed that lower milling force and surface roughness were obtained while machining used a four fluted end mill having a diameter of 8 mm and a helix angle of 55°.