Abstract
This study presents a two-dimensional monitoring system for precise process control of end milling processes that involve the use of small-diameter tools. This system enables the measurement of tool deflections and cutting forces in two directions : the cutting or tangential direction and the feed or normal direction. Furthermore, this monitoring system makes it possible to estimate periodic changes in tool deflection during a given turn. In this study, this system was applied to side-milling using a small-diameter end-mill. The experiment was performed by end milling a steel plate at different depths of cuts and different radial depth of cuts, and feed rates. Tool behavior in side- milling was examined by this system, and it was compared with the tool behavior examined in slotting. In addition, the relation between the machined form of workpiece and the examined tool behavior was considered. The results of the in-process measurement of tool deflection in side- milling suggest that periodic changes in tool deflection during a given turn are related to the rotation angle of the tool and the number of tool edges. Furthermore, prediction of the machined form of workpiece was found to be possible by estimating tool deflection.
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