This paper presents a new method of computing constant scallop height tool paths in 5-axis milling on sculptured surfaces. Usually, iso-scallop tool paths computation methods are based on approximations. The attempted scallop height is modelled in a given plane to ensure a fast computation of the tool path. We propose a different approach, based on the concept of the machining surface, which en...

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 describes the tool life prediction model with end milling EN31 tool steel using P30 Tungsten uncoated carbide tool. The data set from the Taguchi method design is taken. For discussion the effects of cutting speed, feed rate and depth of cut on tool life of P30 are considered. This paper suggests a novel technique for the tool wear measurement based on machine vision. Tool images are...

In micro-milling, cutting forces generate non-negligible tool deflection, which has a significant influence on the machining process and on workpiece accuracy. This paper investigates the tool deflection during micro-milling and its effect on cutting force and surface generation. The distribution of cutting forces acting on the tool is calculated with a mathematical model that considers tool el...

Two types of end milling at partial radial immersion are distinguished in this work, namely; up and down end-milling. They are theoretically given comparative study for a three tooth end miller operating at 0.5, 0.75 and 0.8 radial immersions. 0.5 and 0.8 radial immersion conditions are chosen so that analysis covers situations in which repeat and continuous tool engagements occur while 0.75 ra...

This paper presents an analytical approach for modeling of turn-milling which is a promising cutting process combining two conventional machining operations; turning and milling. This relatively new technology could be an alternative to turning for improved productivity in many applications but especially in cases involving hard-to-machine material or large work diameter. Intermittent nature of...

ABSTRACT Inconel 718 is a difficult-to-cut nickel-based superalloy commonly used in aerospace industry. This paper presents an experimental study of the tool wear propagation and cutting force variations in the end milling of Inconel 718 with coated carbide inserts. The experimental results showed that significant flank wear was the predominant failure mode affecting the tool life. The tool fla...

In this paper, optimum positioning of the conical cutter for five-axis flank milling of slender surfaces is addressed from the perspective of approximating the tool envelope surface to the data points on the design surface following the minimum zone criterion recommended by ANSI and ISO standards for tolerance evaluation. Based on the observation that a conical surface can be treated as a canal...