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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-...

During machining of stainless steels at low cutting -speeds, workpiece material tends to adhere to the cutting tool at the tool-chip interface, forming built-up edge (BUE). BUE has a great importance in machining processes; it can significantly modify the phenomenon in the cutting zone, directly affecting the workpiece surface integrity, cutting tool forces, and chip formation. The American Iro...

The wear behavior of cutting tools directly affects the quality of the machined part. The measurement and evaluation of wear is a time consuming process and is subjective. Therefore, an image-based wear measurement that can be computed automatically based on given image series of cutting tools and an objective way to review the resulting wear is presented in this paper. The presented method fol...

This paper presents an on-line tool wear condition monitoring system for milling. The proposed system was developed taking the cost and performance in practice into account, in addition to a high success rate. The cutting vibration signal is obtained during the cutting process, and then extracting features using time-domain statistical and wavelet packet decomposition algorithms. It would resul...

Research during the past several years has established the effectiveness of acoustic emission (AE)-based sensing methodologies for machine condition analysis and process monitoring. AE has been proposed and evaluated for a variety of sensing tasks as well as for use as a technique for quantitative studies of manufacturing processes. This paper reviews briefly the research on AE sensing of tool ...

This paperpresentsexperimental investigationsandfinite element simulationsonmicro-millingofTi–6Al– 4V alloy with fine grain uncoated and cBN coated micro-end mills. Micro-milling of Ti–6Al–4V using uncoated and cBN coated tungsten carbide micro-end mills are conducted; surface roughness, burr formation and tool wear are measured. Effects of machining parameters on surface roughness, burr format...

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 ...

In recent years, micro/nanoscale diamond cutting tools shaped by focused ion beam (FIB) has been developed to the deterministic fabrication of micro/nano-structures owing to its unprecedented merits of high throughput, one-step, and highly flexible precision capabilities. However, the exposure of a diamond tool to FIB will result in the implantation of ion source material and the irradiation da...