Data maps for material identification in helical milling by spindle power monitoring

Abstract

Hole making on stacked aerospace materials is a major operation during aircraft assembly which poses significant challenges during manufacturing because of different material machinability. Strategies involving smart machining including adapting proper cutting conditions using real time monitoring can lead to significant improvements. This paper is a continuation of our research that uses data map methodology characterized by different specific force regions for workpiece material identification. In this article, spindle power is monitored utilizing CNC machine internal sensor during helical milling of Aluminium and Titanium alloys in a aerospace stack for estimating cutting coefficients. Our previous research addressed the material detection in circular milling of Aluminium and Titanium alloys independently using a force dynamometer. The result shows the applicability of data map technique consisting of axial force coefficients for material identification in helical milling and highlights the significance of stack sequence .