Study on performance in dry milling aeronautical titanium alloy thin-wall components with two types of tools

• Dynamic forces were analyzed in milling thin-wall components with variable chip load.
• Cutting force and tool vibration displacements from experiment were analyzed.
• Variable pitch tool can decrease obviously tool vibration for its’ uniform energy distribution.

Cutting fluid may be considered an accessory which is frequently applied in order to increase material remove rate especially in cutting aerospace alloys where cutting temperature is very high. However the use of cutting fluids is nowadays limited due to the adverse effects such as health of the operator, environmental and economic reasons. In order to overcome these negative effects and meet the demand for environment-friendly cutting techniques, in this work, dry cutting is associated to compare the machinability of the two types of tools such as variable and uniform pitch tools in milling aeronautical thin-wall material Ti6Al4V. The experimental results have shown that the tool vibration is decreased obviously with variable pitch tool compared with uniform pitch tool during milling process of titanium alloy thin-part components. The vibration minimizing characteristics of variable pitch tool is analyzed using fast Fourier transform and wavelet analysis in the whole milling process.