Date of Award


Publication Type

Master Thesis

Degree Name



Mechanical, Automotive, and Materials Engineering

First Advisor

Gaspar, R.


Engineering, Automotive.




This work presents the results of a series of tests undertaken to improve the mill cutting process of the finish milling station used to machine the sprocket face of an aluminum transmission housing. The tests were performed using the actual high volume, transfer line machinery. A series of twenty optimization tests were performed to understand the effects of spindle speed, feedrate, tool path, depth of cut and cutter rotation. It was determined that the optimized machining process improved the average roughness micro finish readings by 32% and 65% in the two areas of concern on the sprocket face. This was accomplished using a milling cutter that was originally producing inferior part quality with baseline parameters. It was found that the optimized process produced an acceptable micro finish of the sprocket face surface throughout the life of the milling cutter, a significant improvement from previous performance. To better understand the structural response of the complex work piece, a finite element analysis model was used to understand predicted deflections when various machining parameters were altered. Modal analysis was performed on the work piece to understand the frequency response functions to form a basis of the natural frequency characteristics of the work piece. This analysis indicated a natural frequency conflict with the second order of tooth passing frequency. This work outlines several techniques that can be used to optimize a machining process with minimal disruption to the manufacturing process.Dept. of Mechanical, Automotive, and Materials Engineering. Paper copy at Leddy Library: Theses & Major Papers - Basement, West Bldg. / Call Number: Thesis2001 .P69. Source: Masters Abstracts International, Volume: 40-03, page: 0735. Adviser: Robert Gaspar. Thesis (M.A.Sc.)--University of Windsor (Canada), 2001.