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The machined TMB offers only a variation in thickness the material and its condition are the same for the entire TMB. The proposed concept of machined TMBs adds this possibility to the existing methods of weight reduction. Local thinning of the part by (chemical) milling is not an option yet for rubber forming parts. The blank is made in a net shape and after forming no additional trimming operations are necessary. The current state of the art process for rubber forming of parts like wing ribs involves milling lightening holes before the forming operation. For many parts, weight is reduced by removing material, like in the machining of lightening holes in sheets, milling pockets in thick sections and creating pockets in sheets by chemical milling. The machined TMB suits the needs of the aerospace industry very well. Benedictus, in Tailor Welded Blanks for Advanced Manufacturing, 2011 8.2.1 Machined tailor made blanks Other scan patterns include spiral, among others, where the cutter starts roughly from the center of the pocket and follows a spiral-like path and gradually moves outward. This is one of the available scan patterns in CAM, called zigzag. The cutting pattern is similar to mowing the lawn in your backyard, where we step sideways at the end of each pass before reversing the mowing direction. The cutter usually moves in one direction, steps sideways, and cuts in the reverse direction. For a pocket milling, the cutter first plunges into the workpiece, then moves around to make a cut. The second NC sequence is pocket milling. Clamping and fixtures are an important issue in practice, which will be discussed in Section 11.4. Notice that in some cases, the cutter may not be able to cut a complete path around the workpiece without colliding with the clamps that hold the workpiece. One practical issue that must be taken into consideration for profile milling is mounting the workpiece to the workbench (or jig table) of a CNC machine. Profile milling sequence: (a) toolpath and (b) milling simulation. and the maximum step depth is ¼ in., it will take two passes for the cutter to go around the workpiece to complete the profile milling.įigure 11.16. Since the (overall) depth of cut is ½ in. The rule of thumb is that the step depth has to be less than the radius of the cutter. A cutter of stronger material (e.g, cutter of carbide inserts) allows for a larger step depth. In general, a cutter of larger diameter has more strength to plunge deeper into the workpiece. Note that step depth is highly related to the size of the cutter among other factors.
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The maximum step depth, which defines how thick the cutter trims around the workpiece in one pass, is set to ¼ in. material intentionally left uncut after completion of the profile pass. Therefore, there will be a layer of ¼ in. Recall that the thickness of the workpiece is ¾ in.
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In this example, the (overall) depth of cut required for the profile milling is set to ½ in. Several important cutting parameters are required for conducting profile milling. Selecting a cutter: (a) detailed geometry of an end mill in Mastercam, (b) cutter in virtual machining simulation, and (c) prescribed tool library in Mastercam.