Research Article
Process Planning and Precision Fabrication of an Aluminum Linkage Arm by CNC Milling and Wire EDM
Issue:
Volume 11, Issue 4, August 2026
Pages:
105-114
Received:
13 July 2026
Accepted:
23 July 2026
Published:
10 August 2026
DOI:
10.11648/j.eas.20261104.11
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Abstract: Linkage arms containing a keyed bore, forked end, pivot hole, and tapered web require coordinated datum control and machining sequence because setup transfer and local stiffness variation can degrade geometric accuracy. This study develops and experimentally evaluates a requirement-driven process-planning framework for the low-volume manufacture of a precision linkage arm from 6061-T6 aluminum alloy using three-axis computer numerical control (CNC) milling and wire electrical discharge machining (WEDM). The objective is to translate the functional requirements into an auditable chain covering datum selection, allowance distribution, tool choice, setup sequence, machining conditions, and final inspection. A single component was fabricated on a VF-1 vertical machining center. The route comprised primary and secondary face generation, staged roughing and finishing, contour milling, circular interpolation, reaming, reverse-side re-fixturing through previously machined features, chamfering, and final WEDM of the internal keyway. The principal bore was completed before WEDM to reference the keyway to the actual bore axis and retain stiffness during bulk material removal. Inspection showed that the principal bore and pivot-hole diameters and the local section thicknesses conformed to the drawing requirements. The reported parallelism deviation was 0.04 mm, while the hole-axis-to-end-face non-perpendicularity was 0.06 mm. A preliminary screening error budget indicated that primary-datum generation and reverse-side re-fixturing accounted for approximately 55–60% of these deviations, identifying setup transfer as the dominant improvement target. The results demonstrate that accuracy depended on datum continuity, controlled re-fixturing, and correct multi-process sequencing rather than on any single operation. The proposed framework provides a practical and traceable basis for low-volume linkage-component manufacture, although repeated trials, formal uncertainty analysis, surface metrology, and mechanical validation remain necessary before industrial process capability can be established.
Abstract: Linkage arms containing a keyed bore, forked end, pivot hole, and tapered web require coordinated datum control and machining sequence because setup transfer and local stiffness variation can degrade geometric accuracy. This study develops and experimentally evaluates a requirement-driven process-planning framework for the low-volume manufacture of...
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,
Nguyen Thi Anh
