Abstract: Development of two real-time surface roughness (Ra) prediction systems for milling operations was attempted. The systems used not only cutting parameters, such as feed rate and spindle speed, but also the cutting current generated and corrected by a clamp type energy sensor. Two different approaches were developed. First, a fuzzy inference system (FIS), in which the fuzzy logic rules are generated by experts in the milling processes, was used to conduct prediction modeling using current cutting data. Second, a neuro-fuzzy system (ANFIS) was explored. Neuro-fuzzy systems are adaptive techniques in which data are collected on the network, processed, and rules are generated by the system. The inference system then uses these rules to predict Ra as the output. Experimental results showed that the parameters of spindle speed, feed rate, depth of cut, and input current variation could predict Ra. These two systems enable the prediction of Ra during the milling operation with an average of 91.83% and 94.48% accuracy by FIS and ANFIS systems, respectively. Statistically, the ANFIS system provided better prediction accuracy than that of the FIS system.
Abstract: 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
of the cutting tool has been decomposed to plane circular feed and
axial linear motion. In this paper, the time varying cutting forces acted
on the side cutting edges and end cutting edges of the flat end cylinder
miller is analysed using a discrete method separately. These two
components then are combined to produce the cutting force model
considering the complicated interaction between the cutters and
workpiece. The time varying cutting force model describes the
instantaneous cutting force during processing. This model could be
used to predict cutting force, calculate statics deflection of cutter and
workpiece, and also could be the foundation of dynamics model and
predicting chatter limitation of the helical milling operations.