Thin wall thin floor monolithic components produced from prismatic blocks are machined on CNC machines by removing material up to 95 %. Components distort because of stresses induced due to severe heat generated and plastic deformation during cutting. Distortion of the components after machining aluminium alloys is major problem faced in aerospace and automobile industries. The volume of the material removed has direct bearing on machining time, which may lead to distortion. The objective of this study is to determine the effect of volume of material removal on the distortion of aluminium 2014 T651 alloy machined from prismatic block. Machining experiments were carried out with 5 different blank sizes to produce a representative component with same machining parameters. Distortion is measured on the face opposite to the machined surface and maximum deviations were used for comparisons between distortion and volume of material removal.
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