Specific force map for smart machining applications with rotating tools

Abstract

Industry 4.0 is the need of the hour in current global market scenario and all the processes are moving toward automation and smart manufacturing. In machining, smart techniques implementation depends on developing a database for decision-making, which is the case for stack drilling in aerospace industry. In this application, choosing one optimal condition for several materials is a challenge due to their different machinability. Hence, material identification techniques are suitable approaches for adapting the cutting parameters in real time, which improves tool life, hole quality, and productivity. In that regard, the goal of the present paper is to create a specific force data map for axial drilling and circular milling processes based on its experimental force and power measurements. To do that, experiments were separately carried out on Titanium and Aluminum workpieces in a range of cutting speed and feed conditions. The results show that specific cutting and feed forces for each material can be identified on distinct regions of the map, without thresholds overlapping. Given that, these maps can be used as a signature to distinguish two metallic materials in real time machining. In this case, the specific data points at the interface layers may offer advantage to accurately identify tool position unlike monitoring gradient of feed forces while drilling stacked materials. Therefore, smart machining techniques seeking cutting parameters optimization can be implemented for a particular material.

Material Identification in Helical Milling for Smart Drilling Applications

“…The following subsections present the cutting power, cutting forces monitored during helical milling of stacks and estimated specific force coefficients data map using cutting power. The data maps of specific coefficients show distinct data points indicating different materials and can be advantageous for material identification especially at interface layers of different material [25]. Cutting power is monitored by utilizing machine internal sensors while cutting forces is monitored by external sensor (Dynamometer) simultaneously, However, specific coefficients are estimated from cutting power signal and this is to verify the possibility of utilising spindle power for material identification.…”