An Experimental Investigation on Productivity and Product Quality During Thin-Wall Machining of Aluminum Alloy 2024-T351

Thin-wall parts have a wide range of applications in aerospace and electronics industry due to their high strength–weight ratio. However, thin-wall parts easily deflect under the generated machining forces, thereby, resulting in loss of product quality, productivity, and form accuracy. Therefore, it is very essential to select proper process parameters. In the present work, an experimental study has been carried out on the influence of productivity parameters on milling force, surface roughness, and dimensional accuracy. It was noted that increase in material removal rate significantly influences the product quality and form accuracy. Higher material removal rate results in chatter vibration which deteriorated the surface finish. This study provides important and valuable guidelines to manufacture thin-wall parts.