Experimental Investigation on Surface Quality and Dimensional Accuracy during Curvilinear Thin-Wall Machining

Precise and accurate machining of thin-walled structures is a difficult task as they often deflect during machining due to their low rigidity. Therefore careful selection of machining parameters and machining approaches are important to achieve desired product quality. This work investigates the influence of process parameters viz. feed rate, number of flutes and machining approaches on performance parameters viz. cutting force, surface finish and deflection error during machining of ultra-thin C shaped wallsmade of aluminum 2024 alloy. By using Taguchi L₉ orthogonal array, systematic experiments were planned and conducted. It was noted that a combined approachi.e. concave + convex machining with four fluted carbide end mill produces superior quality and precise thin-wall components of 700 μm thickness.