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<p>Countersunk holes are widely used in thin-walled aerospace structures, for which low-axial-force and flexible machining are particularly desirable in robot-assisted applications. A innovative combined helical milling (helical milling and then peripheral milling) method for countersunk holes in 6061-T6 aluminum alloy was investigated. A new tapered stepped milling cutter (TSMC) has been proposed. The cutting process was simulated by finite element method and the cutting conclusions were also verified by experiments. The results show that conventional countersunk helical milling fails to completely remove the residual material in the countersunk region, whereas full profile formation can be achieved by introducing an additional peripheral milling process. Compared with conventional helical milling, the proposed method reduced the countersunk diameter deviation from 0.068&#xa0;mm to 0.030&#xa0;mm and lowered the maximum entrance burr height from 34.8&#xa0;μm to 24.7&#xa0;μm. The maximum discrepancy between simulated and experimental cutting forces was 14.89%, indicating acceptable agreement.</p>

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Simulation and experimental study of combined helical milling for countersunk holes

  • 期刊论文

  • 发表日期：

    2026年7月14日

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  • Feng Xiao,
  • Anyuan Jiao,
  • Huiyang Li,
  • Jiawei Cai

摘要

Countersunk holes are widely used in thin-walled aerospace structures, for which low-axial-force and flexible machining are particularly desirable in robot-assisted applications. A innovative combined helical milling (helical milling and then peripheral milling) method for countersunk holes in 6061-T6 aluminum alloy was investigated. A new tapered stepped milling cutter (TSMC) has been proposed. The cutting process was simulated by finite element method and the cutting conclusions were also verified by experiments. The results show that conventional countersunk helical milling fails to completely remove the residual material in the countersunk region, whereas full profile formation can be achieved by introducing an additional peripheral milling process. Compared with conventional helical milling, the proposed method reduced the countersunk diameter deviation from 0.068 mm to 0.030 mm and lowered the maximum entrance burr height from 34.8 μm to 24.7 μm. The maximum discrepancy between simulated and experimental cutting forces was 14.89%, indicating acceptable agreement.