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Commercial cutting tools of sintered high speed steel and carbide were used to heavy milling 6N01-T5 aluminum thin-walled hollow W-shape structures under four kinds of cooling conditions. The results showed that the cutting forces increased dramatically when cutting the weld seam or the intersectant ribbed slab where the value of cutting forces were over ten times bigger than those of cutting the single ribbed slab. Among the four cutting parameters, radial depth of cut was the most significant influence factor and followed by feed rate and axial depth of cut. Spindle speed had a less influence. The optimum combination of cutting parameters for the cutting vibration experiments was 3000 rev/min for the spindle speed, 0.05 mm/tooth for the feed rate, 5 mm for the axial depth of cut and 5 mm for the radial depth of cut. The results also showed the order of the effectiveness of the cooling methods on reducing the cutting force was cryogenic pneumatic mist jet impinging (CPMJI), pneumatic mist jet impinging (PMJI), cryogenic wind and dry cutting. Introduction Aluminum alloy is generally classified in the category of easy-to-cut materials. However, due to the low matrix hardness, high ductility and sticky nature, high chemical activity of the aluminum alloy, there are many machining problems such as tool irregular wear, sever adhesion on the tool face and burrs and marks of pressing/extrusion on the machined surface [1-2]. These problems have a great influence on the efficiency, quality and cost when machining this kind of material. Furthermore, heavy cutting method was generally used when machining aluminum structures so as to improve the efficiency [3]. This causes a high level of cutting force and cutting temperature which leads to the generation of obvious build-up-edge or the melt of the aluminum alloy [3-4]. In this case, a effective cooling method is needed to reduce the cutting temperature. However, the regular cooling method which often uses the regular coolant liquid with large rate of flow may cause the oxidization on the surface of the aluminum alloy and the contamination by the cutting oil which has a detrimental effect on the subsequent welding process of the parts [4]. The expensive special coolant is often applied when heavy machining aluminum alloy structures, which in turn greatly increases the machining cost [5]. In the recent ten years, a quantity of researches have been done on the high/ultra-high speed machining on aluminum alloys but little attention has been given to the study on the heavy cutting frames or thin-walled structures under the medium or low cutting speed [6-13]. For these special structures, a combination cutting parameters of very big axial and radial depth of cut, very high feed rate was often selected when machining [7-8]. The common characters of these special structures are the low stiffness and the high value of cutting temperature, force and vibration [10]. Therefore, a poor machining quality is often obtained and the tool wear rate and the cost of cutting tool are high when compared to the machining of aluminum sheet [11]. Cutting force has an intimate relationship with the cutting vibration, cutting temperature and tool wear patterns [11-13]. In this investigation, a 6N01-T5 aluminum thin-walled hollow W-shape structure was selected as the workpiece and several International Conference on Material Science and Application (ICMSA 2015) © 2015. The authors Published by Atlantis Press 979 kinds of commercial cutting tools were used to investigate the cutting forces and these influence factors under the heavy milling condition. Cutting force has an intimate relationship with the cutting vibration, cutting temperature and tool wear patterns [11-13]. In this investigation, a 6N01-T5 aluminum thin-walled hollow W-shape structure was selected as the workpiece and several kinds of commercial cutting tools were used to investigate the cutting forces and these influence factors under the heavy milling condition.

Cutting Force Investigation when Heavy Milling Welded Aluminum-Thin- Walled Hollow Structure