The chatter is one of the major limitations of the productivity in the ball end milling process. It affects the surface roughness, the dimensional accuracy and the tool life. The aim of this research is to propose the new system to detect the chatter during the ball end milling process by using the wavelet transform. The proposed method is implemented on the 5-axis CNC machining center and the ...

Micro end-milling method is a universal micro manufacturing method, which can be used to fabricating complex 3D structures and parts with many materials. But compared with their micrometer order size, their surface roughness quality is not satisfied. In this paper, the different metal phase grains influences are researched, and the micro end-milling process is described while the material is an...

Purpose: An adaptive control system is built which controlling the cutting force and maintaining constant roughness of the surface being milled by digital adaptation of cutting parameters. Design/methodology/approach: The paper discusses the use of combining the methods of neural networks, fuzzy logic and PSO evolutionary strategy (Particle Swarm Optimization) in modeling and adaptively control...

In this article, an adaptive neural controller for the ball end-milling process is described. Architecture with two different kinds of neural networks is proposed, and is used for the on-line optimal control of the milling process. A BP neural network is used to identify the milling state and to determine the optimal cutting inputs. The feedrate is selected as the optimised variable, and the mi...

Micro-end milling is one of the promising methods for rapid fabrication of features with 3D complex shapes. However, controlling the micro-end milling process to obtain the desired results is much harder compared to that of macro-end milling due to the size effect and uncontrollable factors. The problem is much pronounced when workpiece material is a difficult-to-process material such as titani...

Based on the cutting force theory, the cutting stress in end milling operation was predicted satisfactorily through simulation of using finite element method. The mechanistic force models were introduced in high accuracy force predictions for most applications. The material properties in the simulations were defined based on the cutting force theory, as a function of strain and strain rate wher...

The objective in this work is to generate and discuss the stability results of fully-immersed end-milling process with parameters; tool mass m 0.0431kg, tool natural frequency 5700 rads , damping factor ξ 0 . 0 2 and workpiece cutting coefficient C 3.5 10 Nm ⁄ . Different no of teeth is considered for the end-milling. Both 1-DOF and 2-DOF chatter models of the system are generated on the basis ...

Quality and productivity are two important aspects for manufacturing industries. Modeling and optimization is the best technique applied to find the best manufacturing conditions. This technique has been applied to investigate the optimized design of the cutting process in end milling for Al 6061 alloy in order to provide better surface finish as well as high Material Removal Rate (MRR). The cu...

Tool wear, minimum chip thickness and micro tool geometry are found to have a significant influence on the surface roughness through experimental analysis of the micro-end-milling process. To address these issues, a surface roughness model is developed and validated in this present work. Firstly, experimental analysis for the tool wear and surface roughness was performed based on the micro-end-...