Applicability of Tool Condition Monitoring Methods Used for Conventional Milling in Micromilling: A Comparative Review

Abstract

Micromilling is a contact based material removal process in which a rotating tool with nose radius in microns is fed over a stationary workpiece. In the process small amount of material gets chipped off from the workpiece. Due to continuous contact between tool and workpiece significant damage occurs to the cutting tools. Mitigating tool damage to make micromilling systems more reliable for batch production is the current research trend. In macroscale or conventional milling process a number of methods have been proposed for tool condition monitoring. Few of them have been applied for micromilling. This paper reviews different methods proposed and used in last two decades for monitoring the condition of micromilling tools. Applicability of tool condition monitoring methods used in conventional milling has been compared with the similar ones proposed for micromilling. Further, the challenges and opportunities on the applicability issues have been discussed.

Suppression of the High-Frequency Errors in Surface Topography Measurements Based on Comparison of Various Spline Filtering Methods

“…The analysis of milled surface textures is crucial, especially at the end of the milling process, it is one of the most important criteria used to determine the machinability of particular workpiece materials. Many papers focus on conventional milling [ 76 ] of easily cut workpiece materials or machining at different workpiece inclination angles. However, not many articles focused on the errors in the computation of surface topography parameters with noise occurrence specifications.…”

Evaluation of Chip Formation Mechanisms in the Turning of Sintered ZnO Electro-Ceramics

“…Moreover, the vibrational feedback from the accelerometer can be used to simulate and model the cutting forces and tool tip behavior in the milling units [14]. The tooling condition monitoring is also beneficial in characterizing the end result of the machining processes and the classification of the surface roughness [15]. Usually, multi-sensor accelerometer units are proficient in supporting the milling and machining processes by rendering real-time vibrational feedback of the cutting forces and tooling characteristics [16].…”

Sensitivity of acoustic emission amplitude-energy parameters to change in properties of treated composite

“…Метод АЭ, как показывают обзорные публикации [1][2][3], имеет широкое применение при исследовании различных операций механической обработки материалов (точение, сверление, фрезерование), включая и КМ. Исследования АЭ проводят с анализом факторов, влияющих на параметры регистрируемых сигналов.…”