This paper presents a Kalman filter designed for a cutting force measurement system. The cutting force measurement system is used to measure cutting forces for meso-milling applications. Due to the small magnitude of the cutting forces generated from the meso-milling process, the measurement results are easily distorted by the noise that exists in the measurement system. The object of the Kalma...

This paper presents the prediction of micro-milling forces using the finite element method (FE). An FE model of orthogonal micro-cutting with round cutting edge is developed. The cutting force coefficients are identified from a series of FE simulations at a range of cutting edge radii and chip loads. The identified cutting force coefficients are used to simulate micro-milling forces. The simula...

Machinability aspect is of considerable importance for efficient process planning in manufacturing. Machinability of an engineering material may be evaluated in terms of the process output variables like material removal rate, processed surface finish, cutting forces, tool life, specific power consumption, etc. In this paper, graph theoretic approach (GTA) is proposed to evaluate the cutting fo...

Helical milling operations are used to generate or enlarge boreholes by means of a milling tool. The bore diameter can be adjusted through the diameter of the helical path. The kinematics of helical milling on a three axis machine tool is analysed firstly. The relationships between processing parameters, cutting tool geometry characters with machined hole feature are formulated. The feed motion...

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...

Helical milling operations are used to generate or enlarge boreholes by means of a milling tool. The bore diameter can be adjusted through the diameter of the helical path. The kinematics of helical milling on a three axis machine tool is analysed firstly. The relationships between processing parameters, cutting tool geometry characters with machined hole feature are formulated. The feed motion...

This paper investigates the effect of different cutting parameters (cutting speed, feed rate, and depth of cut) on cutting force components and material removal rate (MRR) in dry and wet hard turning processes. The workpiece material, hardened alloy steel AISI 52100, was machined on a CNC lathe with coated carbide tool under different settings of cutting parameters. Three cutting parameters eac...

In this study, turning operation of Monel K500 copper-nickel super-alloy was evaluated. Ceramic cutting tools with two different cutting noses (conventional and wiper) were utilized. At first, the experimental tests were designed by using central composite design method. After implementation of the tests, the statistical models for output data (surface roughness, cutting force, and flank wear) ...

The application of conventional cutting fluids in machining operations is harmful and not eco-friendly. In this context, the present work focuses on environmental friendly cutting fluids such as vegetable oil based cutting fluids (VBCFs). The objective of this work is to determine the influence of vegetable oil based cutting fluids (sesame and coconut oil) with extreme pressure (EP) additive on...

This study is an investigation of the machinability of experimental Ti-Cu alloys (2, 5, and 10mass% Cu) as new dental titanium alloy candidates for CAD/CAM use. The alloys were slotted with a vertical milling machine and carbide square end mills under two cutting conditions. Their machinability was evaluated through cutting force using a three-component force transducer fixed on the table of th...