This paper presents an mathematical model that establishes the relation between the relevant cutting process parameters and surface quality, cutting forces and rate removal, in deburring process. The construction of cutting tool that one use in determining the experimental data is also presented. The mathematical model is determined by using multifactorial analysis. Directions towards the optim...

Cutting forces prediction is very important for cutting tool’s design and process planning. This paper presents a fuzzy cutting force modelling method using subtractive clustering for learning evaluation. In this method, subtractive clustering, combined with the least-square algorithm, identifies the fuzzy prediction model directly from the information obtained from the sensors. In the micro-mi...

A fuzzy-logic controller (FLC) is designed to automatically adjust feed rate in order to regulate the cutting force of milling processes in a vertical machining center. The FLC has a double-loop structure, consisting of the inner PD (proportional-derivative) velocity-control loop for a feed servo and the outer fuzzylogic force-control loop. Reference cutting forces are well maintained in both n...

An intelligent E-Manufacturing system was developed in this paper. The high speed machining center was rebuilt using 3D CAD system. The moving table (X axis), span column (Y axis), spindle (Z axis) and the tool changing system were modeled precisely. The high speed cutting (HSC) experiments of AL 6061 were carried to obtain the cutting forces and surface roughness for different cutting conditio...

A new nominal uncut chip thickness algorithm for micro-scale end-milling is proposed by considering the combination of an exact trochoidal trajectory of the tool tip and tool run-out, and then the actual uncut chip thickness may be obtained from a comparison between the current accumulative uncut chip thickness and the minimum chip thickness. Due to the intermittency of the chip formation, the ...

A new digital-based model is presented for the prediction cutting forces in 3-axis CNC milling of surfaces. The model uses an algorithm to detect the work-piece/cutter intersection domain automatically for given cutter location (CL), cutter and work-piece geometries. The algorithm uses a voxelization framework to voxelize the cutter helix as well as the work-piece and based on voxel intersectio...

Under normal machining conditions, the cutting forces are primarily due to the bulk shearing of the workpiece material in a narrow zone called the shear zone. However, under finishing conditions, when the uncut chip thickness is of the order of the cutting edge radius, a ploughing component of the forces becomes significant as compared to the shear forces. Predicting forces under these conditio...