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...

Electrochemical micromachining (ECMM) is a non-conventional manufacturing method suitable for the production of microsized components on a wide range of conductive materials. ECMM improves dimensional accuracy and simplifies tool design for machining hard, high strength, heat resistant, and conductive materials into complex shapes. Extremely small interelectrode gaps of the order of few microns...

An autonomous machine tool has been developed to solve fundamental issues with the current command method using NC programs, and some key technologies for its realization have been devised. In the process planning system, various process plans are prepared, and the appropriate process plan can be selected to achieve flexible machining operations. Digital Copy Milling, digitizing the principle o...

This paper investigates the interaction between cutting tool edge radius and material separation due to ductile fracture based on Atkins’ model of machining. Atkins’ machining model considers the energy needed for material separation in addition to energies required for shearing at the primary shear zone and friction at the secondary shear zone. However, the effect of cutting tool edge radius, ...

Recent evolutions on forging process induce more complex shape on forging die. These evolutions, combined with High Speed Machining (HSM) process of forging die lead to important increase in time for machining preparation. In this context, an original approach for generating machining process based on machining knowledge is proposed in this paper. The core of this approach is to decompose a CAD...

We present two methods for process planning of 2.5D machined parts. The first method is based on feature recognition from a 3D model. We embedded the shape and the machining method of two generic classes of machining features in a set of OPS5 rules to form a machining feature recognizer. When successfully recognizing a machining feature, machining instructions, in terms of the tool entrance fac...

An attachable electromagnetic-energy-harvester driven wireless vibration-sensing system for monitoring milling-processes and cutter-wear/breakage-conditions is demonstrated. The system includes an electromagnetic energy harvester, three single-axis Micro Electro-Mechanical Systems (MEMS) accelerometers, a wireless chip module, and corresponding circuits. The harvester consisting of magnets with...

Single Point Diamond Turning (SPDT) experiments conducted on single crystal 6-H Silicon Carbide (SiC) has shown chip formation similar to that seen in the machining of metals. The ductile nature of SiC is believed to be the result of a high pressure phase transformation (HPPT), which generates a plastic zone of material that behaves in a metallic manner. This metallic behavior is the basis for ...

Machining processes such as end milling are the main steps of production which have major effect on the quality and cost of products. Surface roughness is one of the considerable factors that production managers tend to implement in their decisions. In this study, an artificial neural network is proposed to minimize the surface roughness by tuning the conditions of machining process such as cut...

K. Żak, W. Grzesik, M. Prażmowski, Opole University of Technology, Department of Manufacturing Engineering and Automation, Opole, Poland This paper presents a sequential machining process which incorporates CBN hard turning with cryogenic pre-cooling of the workpiece (CHT) and ball burnishing (BB). The main goal of this study was to select machining conditions enhancing the quality of parts mac...