With increased application of mechanical micromachining for creating small features with complex geometries on a broad range of materials, the need for understanding the mechanics of machining at the micro-scale has been recognized. During mechanical micromachining of metals, the tool-workpiece interaction occurs entirely within either a single crystal or a few crystals of the workpiece materia...

The process monitoring and mechanics of fixed abrasive diamond wire saw machining are investigated in this study. New techniques to affix diamond particles to a steel wire core have advanced to make this process feasible for the machining of ceramics, wood, and foam materials. Developments in fixed abrasive diamond wire machining are first reviewed. Advantages of using fixed abrasive diamond wi...

The most common machining methods in machining are turning, milling, drilling and grinding. Significant studies are conducted in machining industry and academic circles in order to measure the cutting force during these processes. This study includes a review of these studies, a categorization of similar ones and detailed information about measurement systems. Through the review of studies, we ...

The machining of fibre reinforced composites is an important activity for optimal application of these advanced materials into engineering fields. During machining, any excessive cutting force has to be avoided in order to prevent any product reject in the last stages of production cycle. Therefore, the ability to predict the cutting forces is essential to select the process parameters necessar...

This paper presents a study the effect of nose radius (Rz-mm) on cutting force components and temperatures during the machining simulation in an orthogonal cutting process for titanium alloy (Ti-6Al-4V). The cutting process was performed at various nose radiuses (Rz-mm) while the depth of cut (d-mm), feed rate (fmm/tooth) and cutting speed (vc-m/ min) were remained constant. The main cutting fo...

As a different approach to the condition monitoring of machining processes by sensor fusion, which has been of great interest over the recent time, this paper presents a novel approach of utilising a single data source to evaluate in-process the overall machining performance in finish turning. The overall machining performance includes the variations of machining performance (chip breakability,...

Due to the widespread applications of fiber reinforced polymer composites in various industries, the machining of these materials to reach the desired shapes, close tolerances and surface finish quality is of great importance. But the composite materials are anisotropic and are mostly prepared in laminated form and, therefore, they have special chip formation behaviour. Among the effective para...

Optimization of process parameters is the key step in response surface methods to achieve high quality without cost inflation. The multi-response optimization of the machining parameters viz, chip-tool interface temperature, main cutting force and feed force on lathe turning of En-31 steel as alloy steel using RSM with grey relational analysis is reported. A grey relational grade obtained from ...

A new machining process model that explicitly includes the effects of the edge hone is presented. A force balance is conducted on the lower boundary of the deformation zone leading to a machining force model. The machining force components are an explicit function of the edge radius and shear angle. An increase in edge radius leads to not only increased ploughing forces but also an increase in ...

In finish-machining, geometric accuracy and surface quality m adversely affected by the tool wear at the minor flank and nose area. This paper describes an investigation into "comprehensive" tool wear estimation, including flank-, crater-. minor flank-, and nose-wear, based on an analysis of dynamic cutting force in oblique machining. The force, measured in terms of its three orthogonal compone...