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Machining of prismatic blocks, removing material up to 85 % on CNC ma‐ chines to produce thin wall thin floor monolithic components replacing multi part assemblies has become common in aerospace industries. The greatest challenge when machining these components is part distortion. Selecting the right kinds of tools and machining parameters is of utmost importance in minimizing distortion. One of the important parameters is the size (diameter) of the cutter. Generally, within a production scenario, the selecting the size of the cutter is driven by the productivity and geometrical constraints of the component. Experience shows that selecting the wrong size of the cutter can lead to distortion and the selecting of a correct size of the cutter depends on heuristics. In order to understand the effect of cutter diameter on distortion, machining experiments were carried out by using different sizes of milling cutter, at constant feed, speed, depth of cut and volume of material removal rate, on a representative thin wall thin floor aluminium alloy (2014A T651) component, holding the part from the bottom, using a shop made vacuum fixture. Machining simulations were also carried out to understand the ma‐ chining characteristics with any change in cutter diameter at constant feed, speed, depth of cut, and material removal rate. Experimental results show that the diameter of a milling cutter has an effect on distortion at constant feed, speed, depth of cut, and volume of material removal rate. © 2015 PEI, University of Maribor. All rights reserved.

Effect of a milling cutter diameter on distortion due to the machining of thin wall thin floor components