An experimental investigation of the influence of cutting parameters on workpiece internal temperature during Al2024-T3 milling
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In the aerospace industry which widely uses aluminum alloys to manufacture aircraft structures, end-milling is a common process to produce the desired components. However, in order to adjust this mechanical process, several complex factors occurring during the cutting stage have to be considered, making the process development difficult. In order to meet efficiency and robustness end, the tool-part interface temperature level is an important issue, in particular for aluminum thin plate milling. One of the issues is caused by the heat generated during the machining in the aluminum part leading to possible residual stresses once the heat is dissipated. This study aims at investigating the influence of cutting parameters on the heat generated during machining and provides guidelines for machining thin plates. A measurement device associated with embedded thermocouples at stationary positions along the tool path in subsurface has been used. Data collected throughout the milling experiments indicated that the workpiece internal-temperatures values rise with the feed decrease. The optimum milling condition was observed for low radial tool immersion, low depth of cut, high cutting speed, and a feed per tooth equal to at least 0.005″ (0.127 mm).
KeywordsMilling Aluminum Cutting temperature Thermocouple Thin plate
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