In this paper, an enhanced mathematical model is presented for the prediction of cutting force system in ball end milling of sculptured surfaces. This force model is also used as the basis for off-line feed rate scheduling along the tool path in order to decrease the cycle time in sculptured surface machining. As an alternative for setting a constant feed rate all along the tool path in rough m...

This paper aims to present the critical issues and methodologies to improve robotic machining performance with flexile industrial robots. Design/methodology/approach – A complete solution using active force control is introduced to address various issues during the robotic machining process. Programming complex couture parts without a CAD model is made easy by using force control functions such...

This paper describes the implementation of an integrated monitoring system for a CNC machine tool and its machining processes such as drilling, milling, turning and grinding. The monitoring system uses a variety of sensors such as force, torque, vibration, acoustic emission, and temperature to monitor the machining processes and the physical condition of the machine tool. The major aim is to im...

An Intelligent Fixturing System (IFS) is currently being developed to hold a family of thin-walled workpieces for machining operations. This is a cost-effective system which uses off-line optimisation of the clamps location and on-line adjustment of clamping forces. As adaptive clamping forces appropriate to the dynamic machining environment are employed, the IFS offers higher quality of machin...

ix CHAPTER 1. GENERAL INTRODUCTION 1 1.1 Background 1 1.2 Motivation 4 1.3 Research Objectives 5 1.4 Dissertation Outline 6 CHAPTER 2. LITERATURE REVIEW 7 2.1 Rapid Prototyping Application in Pattern & Mold Manufacturing 7 2.2 Layer Thickness Algorithm 14 2.3 Tool Size and Machining Parameter Selection 17 2.4 Cutting Force Models 22 2.5 Thin Material Machining 23 2.6 Machining Error Prediction ...

This research proposes an optimized magnetic abrasive machining process that uses an ultra-high-speed system to perform precision machining on a workpiece. The system can process several microns of material, either for machining surface roughness or for machining a workpiece for a precise micro-diameter. The stainless steel workpieces have been machined using an ultra-high-speed magnetic abrasi...

Laser machining efficiency and quality are closely related to gas pressure, nozzle geometry, and standoff distance. Modeling studies of laser machining rarely incorporate gas effects in part because of the complex structure and turbulent nature of jet flow. In this paper, the interaction of a supersonic, turbulent axisymmetric jet with the workpiece is studied. Numerical simulations are carried...

Cutting fluids, usually in the form of a liquid, are applied to the chip formation zone in order to improve the cutting conditions. Cutting fluid can be expensive and represents a biological and environmental hazard that requires proper recycling and disposal, thus adding to the cost of the machining operation. For these reasons dry cutting or dry machining has become an increasingly important ...

The challenges of machining, particularly milling, glass fibre-reinforced polymer (GFRP) composites are their abrasiveness (which lead to excessive tool wear) and susceptible to workpiece damage when improper machining parameters are used. It is imperative that the condition of cutting tool being monitored during the machining process of GFRP composites so as to re-compensating the effect of to...