Development of smart manufacturing framework for micromilling of thin-walled Ti6Al4V

Abstract

Identification of chatter is mostly carried out offline after capturing the machining signals or by analyzing the machined surface after completing or interrupting the machining process. The offline methods for analyzing the machined signals are tedious and not very useful for microcomponents attributed to permanent deformation of thin-wall if chatter has already been occurred during process. Real-time information is necessary to monitor and control the micromilling process. Consequently, a smart manufacturing framework has been developed in the present work to monitor the chatter onset and the deviation in geometrical shape of the thin-wall during micromilling. An interactive web interface has been developed to project the real-time information necessary to monitor the micromilling process. The excitation of natural modes of the thin-walled structure of Ti6Al4V has been observed in real-time on the web browser for micromilling at 80 µm radial depth of cut, 50,000 rpm and a feed rate of 3 µm/flute. The maximum permanent deformation of 97.43 µm for thin-wall has been obtained at 130 µm radial depth of cut. The developed layout of web browser can be used for real-time monitoring of any other machining process as well.