This paper presents the development of a cutting force model for end milling process under various cutting conditions and the tool wear is measured by Scanning Electron Microscope (SEM).This novel approach combines the concept of experimental design and finite element modeling of the cutting process which allows for a fairly accurate prediction of cutting forces with a significantly lower compu...

Metal matrix composites have been increasingly used as materials for components in automotive and aerospace industries because of their improved properties compared with non-reinforced alloys. During machining the selection of appropriate machining parameters to produce job for desired surface roughness is of great concern considering the economy of manufacturing process. In this study, a surfa...

Tool wear increases cutting force, vibration, temperature, etc in end milling and reduces surface finish of the machined work piece. Mathematical model has been developed to predict the tool wear in terms of machining parameters such as helix angle of cutting tool, spindle speed, feed rate, axial and radial depth of cut. Central composite rotatable second order response surface methodology was ...

The machining of thin-walled double side freeform component has many challenges in terms of the geometrical complexity, high-requirement accuracy, and especially low stiffness. This paper surveys the filling method during the milling processes of thin-walled double side freeform component. Firstly, the DEFORM-3D was used to analyze and calculate the surface residual stress which provides a theo...

Received: 20 October 2014 / Accepted: 15 November 2014 Abstract: An approach for determination of the best cutting parameters leading to maximum material removal rate in machining D2 (Die Steel) on vertical milling centre is used. The Response Surface Methodology technique is applied to obtain optimum values of considered parameters in machining D2 (Die Steel) with four flutes carbide end mill ...

This paper is concerned with the optimization of the surface roughness when milling aluminium alloys (AA6061-T6) with carbide coated inserts. Optimization of milling is very useful to reduce cost and time for machining mould. Potential support vector machine (PSVM) is used to develop surface roughness predicted model. Design of experiments method and response surface methodology techniques are ...

This paper presents a new approach for surface roughness (Ra) prediction during milling by using dynamometer to measure cutting forces signals and cutting conditions. End milling machining process of hardened die steel with carbide end mill, was modeled in this paper using the adaptive neuro fuzzy inference system (ANFIS) to predict the effect of machining variables (spindle speed, feed rate an...

This paper describes an efficient method to find the lowest cost tool sequence for rough machining free-form pockets on a 3-axis milling machine. The free-form pocket is approximated to within a predefined tolerance of the desired surface using series of 2.5-D layers of varying thicknesses that can be efficiently removed with flat-end milling cutters. A graph-based method finds an optimal seque...

This paper presents the optimization of high speed milling process parameters with respect to the surface roughness of samples and the study of the Taguchi design application to surface quality in a CNC end milling operation. The Taguchi design is an efficient and effective experimental method in which a response variable can be optimized given various control factors using fewer resources than...

This paper proposes a hybrid WAAM (wire arc additive manufacturing) and milling process (HWMP), and highlights its application in the fabrication of stiffened panels that have wide applications in aviation, aerospace, and automotive industries, etc. due to their light weight and strong load-bearing capability. In contrast to existing joining or machining methods, HWMP only deposits stiffeners l...