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-...

Experimental measurement of the cutting forces in milling processes can be a useful tool to validate standard and non-conventional milling models to be adopted in most industrial applications. As an example, such models can be used to design the machine tool components and fixtures, to choose the technological process parameters and to define process monitoring and diagnostic tools such as moni...

Helical milling operations are used to generate or enlarge boreholes by means of a milling tool. The bore diameter can be adjusted through the diameter of the helical path. The kinematics of helical milling on a three axis machine tool is analysed firstly. The relationships between processing parameters, cutting tool geometry characters with machined hole feature are formulated. The feed motion...

We introduce a new method that approximates free-form surfaces by envelopes of one-parameter motions of surfaces of revolution. In the context of 5-axis computer numerically controlled (CNC) machining, we propose a flank machining methodology which is a preferable scallop-free scenario when the milling tool and the machined free-form surface meet tangentially along a smooth curve. We seek both ...

Helical milling operations are used to generate or enlarge boreholes by means of a milling tool. The bore diameter can be adjusted through the diameter of the helical path. The kinematics of helical milling on a three axis machine tool is analysed firstly. The relationships between processing parameters, cutting tool geometry characters with machined hole feature are formulated. The feed motion...

The cutter runout is very common in machine milling and has a great effect on the surface accuracy. In this paper, a measurement of radial cutter runout in revolving milling tool is proposed by using the laser sensor. A laser beam is projected onto the milling tool edge and subsequently reflected. The diffuse reflection is captured by the sensor and the displacement between the cutter and the l...

This paper introduces a method to determine the tool wear by measured cutting force in Ball-nose End Milling. The features will be extracted from the measured cutting force with different flank wear. As the adaptive window width in wavelet transform is an advantage for analyzing and monitoring the rapid transient of small amplitude of cutting force signals when cutting engagement changes along ...

This paper introduces an adaptive fuzzy logic controller (AFLC) for precision contour machining which adjusts both input and output membership functions simultaneously. The parameters of the proposed controller are self-tuned in real-time according to a continuous measurement of the performance of the controller itself and estimated disturbance values. The adjustment of the membership functions...

This paper presents an optimization post-processing module allowing to improve and to optimize tool-tip milling operations. Moreover, this module verifies and insures milling feasibility of a complex tri-dimensional shape. During such situations, the tool is in contact with the workpiece through a point located on its ball-end mill. Knowing that a relatively large variation of the tool orientat...

All process elements of a reconfigurable manufacturing system should accommodate future changes. This paper looks at one such process element, tool paths, with focus on face milling and pocket milling. Tool paths for the first part are designed to optimize the process outcomes for the initial constraints. Change in market conditions or part design leading to change in cycle time requirements, g...