Article
Engineering, Manufacturing
Lorenzo Morelli, Niccolo Grossi, Antonio Scippa, Gianni Campatelli
Summary: This paper presents a comprehensive classification of the shape of cutting forces causing surface form errors in peripheral end-milling, along with proposed analytical equations to obtain key points defining surface error shape under various cutting conditions and tool geometries. Experimental validation was conducted to prove the reliability and effectiveness of the proposed approach, showing potential for extending knowledge about surface errors in peripheral milling. The proposed formulations could also be utilized to simplify error prediction methods based on simulations or significantly reduce surface measuring time in quality control.
JOURNAL OF MANUFACTURING PROCESSES
(2021)
Article
Engineering, Multidisciplinary
G. Totis, M. Sortino
Summary: Measuring cutting force when milling slender/thin-walled parts is challenging due to structural vibrations that cause inertial disturbances. Signal filtering is the only option to extend the dynamic bandwidth. Non-parametric filters are preferred as they are more practical. A novel non-parametric filter called Superior Optimal Inverse Filter was developed, outperforming existing filters in compensating for dynamics.
Article
Engineering, Mechanical
Niccolo Grossi, Lorenzo Morelli, Antonio Scippa, Gianni Campatelli
Summary: This paper presents a novel approach to accurately identify both radial and axial depth of cut in 2.5-axis peripheral milling operations using cutting force signals analysed in the frequency domain. The proposed method utilizes a normalized cutting force spectrum to estimate the depths of cut, without the need for cutting force coefficients, cutting force direction, or dedicated instrumentation. Numerical and experimental validation demonstrates that the method can accurately determine the depth of cut with a maximum absolute error less than 0.4 mm, making it a promising foundation for force-based cutting condition monitoring systems in peripheral milling.
MECHANICAL SYSTEMS AND SIGNAL PROCESSING
(2022)
Article
Automation & Control Systems
Paolo Parenti, Francesco Puglielli, Massimo Goletti, Massimiliano Annoni, Michele Monno
Summary: Solid ceramic end mills can achieve higher material removal rates for machining heat resistant super alloys, but may have limited tool life and potential heat-related issues. Study showed cutting strategy and speed significantly affect cutting signals and workpiece integrity.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Mechanics
Chao Li, Chunzheng Duan, Xiaodong Tian, Chao Wang
Summary: A mechanistic model considering the bottom edge cutting effect and the anisotropic characteristics of the material is proposed in this paper to accurately predict cutting forces. The model was validated through a series of milling experiments and can be used to predict the cutting force of various parts of the cutter and any feed direction.
COMPOSITE STRUCTURES
(2024)
Article
Engineering, Electrical & Electronic
Yung Ting, Hsin-Yuan Chen, Jun-Hao Chen, Suprapto, Chih-Hsuan Yu
Summary: The developed multi-axis sensor made of flexible PVDF thin film is designed for cutting force measurement in milling process. It features six electrodes in a certain pattern for accurate measurement and a cutting-force model that computes feed force, transverse force, and tangential force. The sensor, combined with digital signal processing unit and wireless communication device, effectively measures cutting force with satisfactory accuracy.
SENSORS AND ACTUATORS A-PHYSICAL
(2021)
Article
Engineering, Multidisciplinary
Zequan Yao, Ming Luo, Jiawei Mei, Dinghua Zhang
Summary: A low-cost and adaptable single-point monitoring method based on one acceleration sensor is proposed to monitor the milling process more conveniently and accurately. By establishing a spatial vibration attenuation model and calculating vibration intensity, the model shows high precision and accuracy in analyzing the relative errors between measured and calculated cutting forces under different vibration conditions.
Article
Chemistry, Physical
Lukasz Zylka, Rafal Flejszar, Pawel Lajmert
Summary: The impact of cutting-edge microgeometry on cutting forces in the finish milling of a 7075-aluminium alloy was analyzed. The influence of rounding radius of cutting edge and the size of the margin width on cutting-force parameters was analyzed. Experimental tests were carried out for different cross-sectional values of the cutting layer. Mathematical models of the relationship between force parameters and the radius of the rounded cutting edge and the width of the margin were developed.
Article
Engineering, Civil
Mehmet Alper Sofuoglu, Selim Gurgen
Summary: Unlike metals, polymers are highly affected by the heat generation during machining. This study investigated the effect of SiC fillers on the machinability of UHMWPE polymer composite. The results showed that SiC fillers can reduce cutting forces and cutting temperatures.
ARCHIVES OF CIVIL AND MECHANICAL ENGINEERING
(2022)
Article
Engineering, Manufacturing
Lucia Lizzul, Marco Sorgato, Rachele Bertolini, Andrea Ghiotti, Stefania Bruschi
Summary: This study focuses on ball end milling of Ti6Al4V alloys manufactured using both additive and conventional methods, exploring the impact of unique microstructural features induced by additive manufacturing on machining operations. The results indicated that the additively manufactured alloy exhibited better machinability than the conventionally manufactured one only under specific conditions, where the cutting edge was parallel to certain alpha phase colonies. This allowed for easier material removal by locally reducing resistance to cutting.
JOURNAL OF MANUFACTURING PROCESSES
(2021)
Article
Engineering, Manufacturing
Min Wan, Dan-Yang Wen, Wei-Hong Zhang, Yun Yang
Summary: The characteristic of low stiffness of micro mills leads to changes in tool deflections, resulting in deviations of actual cutting parameters such as cutting directions and trajectories. Existing studies have rarely considered the influence of these deviations on cutting forces. This article presents a theoretical method that predicts micro milling forces by incorporating the effects of tool deflections. The method derives analytical formulae for determining actual in-process cutting edge positions and instantaneous cutting directions based on tool deflections calculated using the cantilever beam theory. Experimental tests demonstrate the accuracy of the proposed method in predicting cutting forces and cutting edge trajectories compared to classic models that do not consider changes in cutting directions caused by tool deflections.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
Article
Engineering, Mechanical
G. Totis, M. Sortino
Summary: High-end piezoelectric dynamometers with a wide frequency bandwidth are necessary for characterizing cutting mechanics during high-speed milling and micromilling applications. Current filters have limitations, prompting the development of a novel non-parametric filter that considers input force direction and location for improved results.
MECHANICAL SYSTEMS AND SIGNAL PROCESSING
(2022)
Article
Engineering, Multidisciplinary
Junichi Kouguchi, Hayato Yoshioka
Summary: A new monitoring method for milling process using signal analysis of acceleration sensors is proposed in this research, which can solve the difficulty in estimating cutting forces for small diameter tools.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Chemistry, Physical
Agata Felusiak-Czyryca, Marek Madajewski, Pawel Twardowski, Martyna Wiciak-Pikula
Summary: Inconel 718 alloy is commonly used in aerospace and marine industries due to its properties, but its difficult machinability poses challenges. Turn-milling is a method that can alleviate the difficulty, but tool wear remains a concern due to increased forces during machining.
Article
Engineering, Manufacturing
Mithilesh K. Dikshit
Summary: Due to the complex geometry, predicting the forces in ball end milling process (BMP) is a challenging task. The cutting forces generated during BMP have significant effects on various aspects of machining characteristics. In this research, a new mathematical model based on the linear mechanistic method is proposed to determine the force coefficients. Validation experiments show that the predicted forces are remarkably close to the experimental results.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE
(2022)
