This paper presents an advance in monitoring and process control of surface roughness in CNC machine for the turning and milling processes. An integration of the in-process monitoring and process control of the surface roughness is proposed and developed during the machining process by using the cutting force ratio. The previously developed surface roughness models for turning and milling proce...

In high speed and high precision machining applications, it is important to monitor the machining process in order to ensure high product quality. For this purpose, it is essential to develop a dynamometer with high sensitivity and high natural frequency which is suited to these conditions. This paper describes the design, calibration and performance of a milling torque sensor based on piezores...

Optimal and intuitive robotic machining is still a challenge. One of the main reasons for this is the lack of robot stiffness, which is also dependent on the robot positioning in the Cartesian space. To make up for this deficiency and with the aim of increasing robot machining accuracy, this contribution describes a solution approach for optimizing the stiffness over a desired milling path usin...

For rotating-tool machining, such as milling, line boring, and cylinder boring, the tool rotation causes the machining force on each tooth to rotate repetitively relative to the inertial coordinate frame. This is quite different than stationary-tool machining, such as turning or boring with a stationary boring bar, in which the force directions are fixed relative to the inertial frame. Although...

Using a machine learning approach, this study investigates the effects of machining parameters on the energy consumption of a milling machine tool, which would allow selection of optimal operational strategies to machine a part with minimum energy. Data-driven prediction models, built upon a nonlinear regression approach, can be used to gain an understanding of the effects of machining paramete...

Mechanical machining processes are common manufacturing strategies to re-shape materials to desired specification. The mechanistic approach has revealed the mechanics of the machining processes with various parameters determined. The aim of this work is to investigate the impact of swept angle optimization and their influence on the specific cutting energy in milling AISI 1045 steel alloy. This...

In recent years, advanced materials with unique metallurgical properties such as super alloys, composites and ceramics have been developed to meet the demands of extreme applications. While these materials are harder, tougher, less heat sensitive and more resistant to corrosion and fatigue, they are also difficult to machine. Advanced materials are being widely used these days not only in the a...

5-Axis milling simulations in CAM software are mainly used to detect collisions between the tool and the part. They are very limited in terms of surface topography investigations to validate machining strategies as well as machining parameters such as chordal deviation, scallop height and tool feed. Z-buffer or N-Buffer machining simulations provide more precise simulations but require long com...

Accurate prediction on energy consumption in machining is helpful to evaluate process energy characteristics and choose process methods for energy saving. Specific energy consumption expresses the required energy consumption when cutting unit volume material. The Back Propagation (BP) neural network prediction method for specific energy consumption in machining is set up in the paper. The predi...

In this study, diamond films are deposited by using hot filament chemical vapor deposition (HFCVD), Nanocrystalline diamond (NCD) coated cemented tungsten carbide (WC-Co) milling tools are characterized, compared with microcrystalline diamond (MCD) and composite diamond coated ones, in terms of morphology with field emission scanning electron microscope (FESEM). Moreover, the diamond coated too...