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...

Tool wear is an important factor that affects the quality and machining accuracy of aeronautical structural parts in milling process. It essential to monitor tool titanium alloy machining. The traditional features such as root mean square (RMS), kurtosis, wavelet packet energy spectrum are related not only status but also parameters, thus monitoring under fixed parameters. This paper proposes a...

Thin-walled parts are widely used in the aviation industry. It is mainly carried out with end mills and accompanied by self-oscillation during rough milling. They negatively affect quality of machined surface. Therefore, it important to model taking into account dynamics milling process predict accuracy. In early works authors, mechanism profile forming surface was determined. this case, identi...

High-speed milling operations of thin walls are often limited by the so-called regenerative effect that causes poor surface finish. The aim of this paper is to examine the link between chatter instability and surface roughness evolution for thin wall milling. Firstly, the linear stability lobes theory for the thin wall milling optimisation was used. Then, in order to consider the modal interact...

The paper deals with the problem of compliance errors compensation in robotic-based milling. Contrary to previous works that assume that the forces/torques generated by the manufacturing process are constant, the interaction between the milling tool and the workpiece is modeled in details. It takes into account the tool geometry, the number of teeth, the feed rate, the spindle rotation speed an...

Undesirable burrs are created in most of the machining processes. A burr is a plastically deformed material that remains attached at the workpiece edges after machining, and must be removed for making the parts to function effectively. The main objective of the present work is to explore the suitable condition to obtain minimum or negligible burr around the edge of a machined product at wet con...

Carbon fiber reinforced plastics (CFRP) have good physical properties, such as high specific strength and high specific modulus. However, cutting delamination, tearing and burr, etc. often occur in the machining process of CFRP, which results in the uncontrollability of machining surface quality and serious tool wear. In this paper, milling of CFRP with a staggered cutter was carried out, the c...

The problem of determining the inputs to the rotary axes of a 5–axis CNC machine is addressed, such that relative variations of orientation between the tool axis and surface normal are minimized subject to the constraint of maintaining a constant cutting speed with a ball-end tool. In the context of an orientable–spindle machine, the results of a prior study are directly applicable to the solut...

Milling is one of the most common manufacturing processes in industry. Despite recent advances in machining technology, productivity in milling is usually reduced due to the process limitations such as high cutting forces and stability. If milling conditions are not selected properly, the process may result in violations of machine limitations and part quality, or reduced productivity. The usua...