Deform 3D Simulation and Experimental Investigation of Fixtures with Support Heads

Abstract

Thin-walled aluminium parts are employed in a variety of industries, including construction and aerospace. If they are treated to a greater quantity of milling, they are more resistant to deformation. As a result, the stability of the work parts degrades, and the surface roughness increases as a result of this factor. This work proposes the use of a well-designed fixture with support heads to lessen the deformation produced by square thin-walled aluminium plate milling. The suggested fixture system's support heads are comprised of high-carbon steel. The milling experiment is carried out in a CNC Machining centre under machining settings similar to DEFORM 3D-Simulation. The experimental results are validated by measuring surface roughness with the SURFTEST SJ-210 portable Surface Roughness tester in two scenarios: without and with fixtures used during the milling operation. As a result of employing this fixture with support heads to reduce deformation, surface roughness values are reduced by a minimum of 3% to a maximum of 19%. As a result, it has been demonstrated that the proposed fixture with support head may be used to reduce distortion in thin-walled aluminium plates

Investigation of Machining Parameters in Thin-Walled Plate Milling Using a Fixture with Cylindrical Support Heads

“…Jing et al [20] investigated the effects of micro-endmilling cutting parameters on machined surface roughness to determine the best operating conditions. Muthu Mekala et al [21] designed and developed a new fixture to minimize the surface roughness in the end milling of Al6061 workpiece. They concluded that the proposed fixture with the support heads greatly reduces the deformation in the work piece, which significantly impacted the surface quality.…”