Abstract: This paper presents an advance in monitoring and
process control of surface roughness in CNC machine for the turning
and milling processes. An integration of the in-process monitoring
and process control of the surface roughness is proposed and
developed during the machining process by using the cutting force
ratio. The previously developed surface roughness models for turning
and milling processes of the author are adopted to predict the inprocess
surface roughness, which consist of the cutting speed, the
feed rate, the tool nose radius, the depth of cut, the rake angle, and
the cutting force ratio. The cutting force ratios obtained from the
turning and the milling are utilized to estimate the in-process surface
roughness. The dynamometers are installed on the tool turret of CNC
turning machine and the table of 5-axis machining center to monitor
the cutting forces. The in-process control of the surface roughness
has been developed and proposed to control the predicted surface
roughness. It has been proved by the cutting tests that the proposed
integration system of the in-process monitoring and the process
control can be used to check the surface roughness during the cutting
by utilizing the cutting force ratio.
Abstract: This paper presents a complete procedure for tool path
planning and blade machining in 5-axis manufacturing. The actual
cutting contact and cutter locations can be determined by lead and tilt
angles. The tool path generation is implemented by piecewise curved
approximation and chordal deviation detection. An application about
drive surface method promotes flexibility of tool control and stability
of machine motion. A real manufacturing process is proposed to
separate the operation into three regions with five stages and to modify
the local tool orientation with an interactive algorithm.