Orientador: Paulo Roberto de Aguiar / Banca: André Nunes de Souza / Banca: Milton Vieira Júnior / Resumo: Os processos de usinagem são de extrema importância no ramo de indústria metalúrgica, uma vez que quase todas as peças de metais em que se exige uma alta precisão e qualidade de acabamento são produzidas por meio destes processos. Dentre os processos de usinagem destaca-se o processo de retificação, por sua precisão e bom acabamento. É essencial que se conheça bem este processo, já que por ser a última etapa da manufatura, qualquer problema compromente a peça e perde-se o trabalho realizado em todas as etapas anteriores. O presente trabalho visa um estudo comparativo entre a força de corte na retificação medida com um dinamômetro piezelétrico e a potência elétrica do motor que aciona o rebolo. A força de corte é reconhecida como sendo a principal variável de estudos dos processos de usinagem. Tradicionalmente a força de corte é tomada por meio de um dinamômetro, porém este é um dispositivo relativamente caro e de difícil montagem. Usualmente, a força no processo de retificação é tomada por meio de um sensor de corrente, obtendo-se um sinal analógico proporcional à potência consumida pelo motor. Entretanto, esta potência não corresponde à potência mecânica utilizada no corte, e, portanto, imprecisões ocorrem. Neste trabalho, os sinais de potências elétricas e força de corte foram coletados com alta taxa de aquisição, com variações de profundidade de corte e da frequência do motor que aciona o rebolo. Os resultados obtidos mostram que os sinais de potência elétrica do motor que aciona o rebolo sempre foram proporcionais aos sinais de força de corte. Desta forma, é possível o dinamômetro na retificação por sensores de corrente e tensão, com resultados confiáveis. / Abstract: The machining processes are of great importance in the metallurgical industry, since all the metal workpieces demanding high precision and finishing quality are produced through these processes. Among the machining processes the grinding process can be highlighted by its precision and superior finishing. As being the last manufacturing stage, it is very important to have sound knowledge of the grinding process because minor problems can jeopardize the ground part, and then all the previous manufacturing operations will also be lost. This work aims at comparing the cutting force between the one measured through a piezoelectric dynamometer and that one measured by electrical power of the induction motor that drives the grinding wheel. The cutting force is acknowledged as being the most important variable for studying the machining processes. Traditionally, the cutting force is taken by a piezoelectric dynamometer, which is relatively expensive equipment besides requiring a nontrivial setup. Generally, the cutting force in the grinding process is taken by a Hall Effect current sensor to produce an analog signal proportional to the power consumed by the electric motor. However, that power does not correspond to the mechanical power used to grind, and thus imprecision takes place. In this work, the electric power and cutting force were collected by using a high samplinf the rate acquisition for several cutting depths and two electrical frequencies to drives the induction motor. The results showed the electric power signals behaved, in general, proportional to the cutting force measured by the dynamometer. Thus, the Hall Effect curret and voltage sensors can be replaced by dynamometer in the grinding process with reliable results. / Mestre

Este trabalho apresenta estudos de usinabilidade de chapas MDF (Medium Density Fiberboard), tendo por objetivo principal efetuar uma análise do desempenho de corte em relação à qualidade da superfície usinada e à força específica de corte paralela necessária, a fim de se verificar a influência dos parâmetros estudados para operações de usinagem de acabamento e desbaste, respectivamente. No estudo para operação de acabamento verificou-se a influência da espessura de corte,velocidade de avanço e sentido de corte, em operação de fresamento cilíndrico periférico, sobre a rugosidade superficial da borda das chapas MDF. Uma fresadora vertical foi utilizada para gerar as superfícies, cuja rugosidade superficial foi medida por um perfilômetro de apalpamento. No estudo para operação de desbaste, a força específica de corte paralela foi avaliada em função da variação do ângulo de saída, da espessura de corte e da profundidade de corte, em operação de corte ortogonal. Para tanto, foram empregadas uma plaina limadora e uma célula de carga de extensômetros resistivos, conectada a um programa de aquisição e análise de dados. A partir da análise dos resultados obtidos, foi possível identificar a influência de cada parâmetro de corte empregado. / This work presents a MDF (Medium Density Fiberboard) machinability study aiming to carry out a cutting performance analysis regarding to surface quality and parallel specific cutting force, in order to verify the cutting parameters effect on the finishing and roughing machining operations, respectively. In the finishing study, it was verified the effect of the cutting thickness, cutting speed and direction of cutterhead rotation with relation to feed direction, in peripheral milling, on the MDF edges surface roughness. The surfaces were developed by a moulder, which roughness were measured by a stylus perfilometer. In the roughing study, the parallel specific cutting force was assessed in relation to the variation of the rake angle, cutting thickness and depth of cut, for the orthogonal cut. For this, it was used a planing machine and a resistance dynamometer, coupled in a data acquisition and analysis system. From the analysis of the obtained results, it was possible to identify the influence of each cutting parameter considered.

Cutting forces and vibrations are essential parameters in the assessment of a cutting process. As the energy consumption in the machining process is directly affected by the magnitude of the cutting forces it is of vital importance to design cutting edges and select process conditions that will maintain high tool performance through reduced energy consumption. The vibrations are often the cause of poor results in terms of accuracy, low reliability due to sudden failures and bad environmental conditions caused by noise. The goal of this work is to find out how the cutting edge and cutting conditions affect the entry conditions of the machining operation. This is done utilizing experimental methods and appropriate theoretical approaches applied to the cutting forces and vibrations. The research was carried out through three main studies beginning with a force build-up analysis of the cutting edge entry into the workpiece in intermittent turning. This was followed by a second study, concentrated on modelling of the entry phase which has been explored through experiments and theory developed in the first study. The third part was focused on the influence of the radial depth of cut upon the entry of cutting edge into the workpiece in a face milling application. The methodology for the identification of unfavourable cutting conditions is also explained herein. Important insights into the force build-up process help addressing the correlation between the cutting geometries and the rise time of the cutting force. The influence of the nose radius for a given cutting tool and workpiece configuration during the initial entry is revealed. The critical angle i.e. the position of the face milling cutter that results in unfavourable entry conditions has been explained emphasizing the importance of the selection of cutting conditions. Finally, the theoretical methods utilized for the evaluation of the role of cutting edge geometry within entry phase dynamics has been explored. This has revealed the trends that are of interest for selection of cutting conditions and cutting edge design.

Haptic devices and haptic rendering is an important topic in the burgeoning field of virtual reality applications. In this thesis, I describe the design and implementation of a cutting force model integrating a haptic device, the PHANToM, with a high &ndash / powered computer. My goal was to build a six degree &ndash / of &ndash / freedom force model to allow user to interact with three &ndash / dimensional deformable objects. Methods for haptic rendering including graphical rendering, collision detection and force feedback are illustrated, implementation of haptic rendering system is introduced, and application is evaluated to explore the effectiveness of the system.

Thesis (MEng)--Stellenbosch University, 2015. / ENGLISH ABSTRACT: Efficient face milling of titanium alloys provides a global challenge. Difficult-to-cut super alloys such as Ti-6Al-4V is considered the “workhorse” material for aerospace components. During the machining of aerospace components, 80% – 90% of the material is removed. This requirement drives the innovation for machines and tooling to become more efficient, while driving down costs. In South Africa, this requirement is no different. Due to the historic practice of exporting valuable minerals such as Ilmenite, leucoxene and rutile, South Africa does not enjoy many of financial benefits of producing value added titanium alloy products. The Titanium Centre of Competence (TiCoC) is aimed at creating a South African titanium manufacturing industry by the year 2020. More specifically, the roughing of Ti-6Al-4V aerospace components has been identified as an area for improvement. The thermal conductivity of Ti-6Al-4V is significantly lower than that of other “workhorse” metals such as steel or aluminium. Therefore, heat rapidly builds up in the tool tip during high speed machining resulting in shortened tool life and increased machining costs. Hence the ongoing developments in the field of cooling methods for high speed machining. The latest development in high pressure cooling (HPC) is split tools that deliver coolant into the cutting interface via flat nozzles in the rake face of the insert. Although it has been released recently and limited to a single supplier, this cooling method is commercially available, yet little is known about its performance or application conditions. The operational characteristics of split tools are studied by answering set research questions. A dynamometer was used to measure the tangential cutting forces during 11 cutting experiments that follow a three-factor factorial design at two levels and with three centre points. A second-order model for predicting the tangential cutting force during face milling of Ti-6Al-4V with split tools was fit to the data at 95% confidence level. A predictive cutting force model was developed in terms of the cutting parameters: (1) Axial depth of cut (ADOC), (2) feed per tooth and, (3) cutting speed. The effect of cutting parameters on cutting force including their interactions are investigated. Data for chip evacuation, surface finish and tool wear are examined and discussed. Practical work was done at a selected industry partner to determine: (1) impact of an analytical approach to perform process development for aerospace component roughing, (2) determine the feasibility of implementing split tools to an existing process. A substantial time saving in the roughing time of the selected aerospace component was achieved through analytical improvement methods. Furthermore it was found that the split tools were not a suitable replacement for current tooling. It was established that certain critical operational requirements of the split tools are not met by the existing milling machine at the industry partner. / AFRIKAANSE OPSOMMING: Doeltreffende masjinering van titaan allooie bied `n wêreldwye uitdaging. Moeilik-om-te-sny super allooie soos Ti-6Al-4V word as die “werksesel” materiaal vir lugvaart komponente beskou. Gedurende die masjinering van lugvaart komponente word 80% - 90% van die materiaal verwyder. Dit is hiérdie behoefte wat die innovering van masjien -en snygereedskap dryf om dit meer doeltreffend en finansieël vatbaar te maak. Die Suid Arikaanse behoefte vir doeltreffende snygereedskap vir Ti-6Al-4V masjinering stem ooreen met hierdie internationale behoefte. Die geskiedkundige Suid Afrikaanse praktyk om onverwerkte, waardevolle minerale soos Ilmeniet, rutiel en leucoxene uit te voer, kniehalter die land se kans om winste uit verwerkte titaan allooi produkte te geniet. Die “Titanium Centre of Competence” (TiCoC) se mikpunt is om `n Suid Afrikaanse titaanproduk vervaardigingsmark op die been te bring teen 2020. Stellenbosch Universiteit se funksie, binne hierdie strategiese raamwerk, fokus op hoë spoed masjinering van Ti-6Al-4V lugvaart komponente. Die hitte geleidingsvermoë van Ti-6Al-4V is noemenswaardig laer as die van ander “werksesel” materiale soos byvoorbeeld staal of alumium. Om hierdie rede word hitte in die freesbeitelpunt gedurende hoë spoed masjinering opgeberg. Dit verkort gereedskap leeftyd en verhoog masjinerings kostes. Daarvandaan deurlopende ontwikkelinge in verkoelingsmetodes vir hoë spoed masjinering. Die mees onlangse ontwikkeling in hoë druk verkoeling is “split tools” wat koelmiddel na die snyoppervlak deur middel van langwerpige gleufies in die hark gesig van die beitelpunt lewer. Hierdie tegnologie is op die mark beskikbaar, maar slegs deur `n enkele verskaffer. Daar is ook geen akademiese publikasies wat oor Ti-6Al-4V masjinering met “split tools” handel nie. Die verrigtings vermoë en toepassings gebied vir die gereedskap is steeds onbekend. 'n Dinamometer is gebruik om die tangensiale snykragte tydens 11 sny eksperimente te meet. Die eksperiment ontwerp is faktoriaal van aard en bevat drie faktore en drie middelpunte oor twee vlakke. `n Kwadratiese model is geskik om die data op 95% vertroue vlak voor te stel en voorspellings mee te maak. Die voorspellingsmodel is ontwikkel in terme van: (1) Diepte van snit, (2) voertempo, en (3) Snyspoed. Die invloed van die drie parameters op die tangentiale snykrag, asook invloed met mekaar word ondersoek. Verdere data in verband met materiaal verwydering, oppervlak afwerking en beitel slytasie word ook bespreek. Praktiese werk is met behulp van `n bedryfsvennoot gedoen om vas te stel: (1) die impak van 'n analitiese benadering en ontwikkelings proses op die uitrof van lugvaart komponente, (2) en om die lewensvatbaarheid van implementering van “split tools“ aan 'n bestaande proses te bepaal. `n Noemenswaardige besparing is sodoende behaal. Dit is verder bevind dat “split tools” nie `n geskikte plaasvervanger vir die huidige snygereedskap is nie. Die rede daarvoor is gedeeltelik omdat die huidige freesmasjien by die bedryfsvennoot nie aan die kritiese operasionele vereistes van die gereedskap vervaardiger voldoen nie.

Orientador: Alessandro Roger Rodrigues / Resumo: A microusinagem é um dos processos de fabricação capaz de produzir produtos ou geometrias de precisão e complexidade com detalhes menores que 1 mm. Contudo, para um melhor desempenho do processo de usinagem associado à qualidade do produto, entender a interação peça-ferramenta é fundamental. Esta pesquisa determinou a influência do tipo de corte e do avanço da ferramenta no desgaste da fresa (ferramenta), na energia específica de corte (processo) e na rugosidade (peça), ao empregar a operação de microfresamento de topo no aço COS AR60 de grãos ultrafinos. Os ensaios foram realizados em um centro de usinagem Romi D600 com a adaptação de um cabeçote de alta rotação (60 krpm) sem aplicação de fluido de corte. Microfresas de topo reto (Ø 800 µm) com substrato de metal duro e revestidas com TiAlN foram aplicadas nos testes. A profundidade de usinagem e a velocidade de corte foram mantidas constantes em 160 µm e 60 m/min, respectivamente. Foram variados o avanço por dente (3 e 10 µm/z) e o tipo de corte (simétrico em cheio e em face e assimétrico concordante e discordante). Análise de Variância (ANOVA) com intervalo de confiança de 95% foi aplicada a cada uma das três réplicas. Os resultados indicaram que os níveis de desgaste e a redução do diâmetro da microfresa são influenciados pelo avanço da ferramenta e tipo de corte. As maiores reduções no diâmetro (≈11%) foram devido ao impacto periódico da aresta de corte na peça e não pelo efeito de sulcamento (≈4%). Além disso, para o pe... (Resumo completo, clicar acesso eletrônico abaixo) / Abstract: Micro-machining is one of the processes feasible for generating geometries or parts with precision and complexity regarding dimensions smaller than 1 mm. However, the achievement of enhanced machining performance and product quality requires a prior understanding on the tool-workpiece interface. This research detemined the influence of cutting type and cutting feed on wear (tool), specific cutting force (process) and surface roughness (workpiece) when cutting the ultrafine-grained steel COS AR60 under end milling strategy. Machining tests were performed in a CNC machining centre Romi D600 provided with a high-speed spindle (60kpm) without cutting fluid application. TiAlN coated carbide endmill (Ø 800 μm) was used for straight cut with 60 m/min cutting speed, 160 μm depth of cut and feed per tooth of 3 and 10 μm. Analysis of Variance (ANOVA) with confidence interval of 95% was applied to the three runs of each cutting sets. The results have shown that tool wear levels and tool effective diameter are influenced by tool feed and cutting type. Hence, intermittent impact of tool’s cutting edges into the workpiece (≈11%) during cutting revealed to be the major cause of tool wear when compared to cutting mechanism dominated by ploughing (≈4%). Regarding experimental sets with cutting length of 98,018 m there was a predominance of tool edge chipping over abrasion and adhesion when performing face cutting with ploughing at 4.2%. On the other hand, if ploughing increases to 14.3% the m... (Complete abstract click electronic access below) / Mestre

Submitted by Flávio Henrique Manarelli (flaviomanarelli@gmail.com) on 2018-11-01T23:57:49Z No. of bitstreams: 1 Dissertação_Flávio Henrique Manarelli.pdf: 2986064 bytes, checksum: edc4536a4c2ec5e96e1c49c52019885f (MD5) / Approved for entry into archive by Cristina Alexandra de Godoy null (cristina@adm.feis.unesp.br) on 2018-11-08T19:00:53Z (GMT) No. of bitstreams: 1 manarelli_fh_me_ilha.pdf: 2986064 bytes, checksum: edc4536a4c2ec5e96e1c49c52019885f (MD5) / Made available in DSpace on 2018-11-08T19:00:54Z (GMT). No. of bitstreams: 1 manarelli_fh_me_ilha.pdf: 2986064 bytes, checksum: edc4536a4c2ec5e96e1c49c52019885f (MD5) Previous issue date: 2018-09-03 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / A microusinagem é um dos processos de fabricação capaz de produzir produtos ou geometrias de precisão e complexidade com detalhes menores que 1 mm. Contudo, para um melhor desempenho do processo de usinagem associado à qualidade do produto, entender a interação peça-ferramenta é fundamental. Esta pesquisa determinou a influência do tipo de corte e do avanço da ferramenta no desgaste da fresa (ferramenta), na energia específica de corte (processo) e na rugosidade (peça), ao empregar a operação de microfresamento de topo no aço COS AR60 de grãos ultrafinos. Os ensaios foram realizados em um centro de usinagem Romi D600 com a adaptação de um cabeçote de alta rotação (60 krpm) sem aplicação de fluido de corte. Microfresas de topo reto (Ø 800 µm) com substrato de metal duro e revestidas com TiAlN foram aplicadas nos testes. A profundidade de usinagem e a velocidade de corte foram mantidas constantes em 160 µm e 60 m/min, respectivamente. Foram variados o avanço por dente (3 e 10 µm/z) e o tipo de corte (simétrico em cheio e em face e assimétrico concordante e discordante). Análise de Variância (ANOVA) com intervalo de confiança de 95% foi aplicada a cada uma das três réplicas. Os resultados indicaram que os níveis de desgaste e a redução do diâmetro da microfresa são influenciados pelo avanço da ferramenta e tipo de corte. As maiores reduções no diâmetro (≈11%) foram devido ao impacto periódico da aresta de corte na peça e não pelo efeito de sulcamento (≈4%). Além disso, para o percurso de corte adotado de 98,018 m, com 4,2% da usinagem em sulcamento ou inexistente no corte em face, houve predominância de avarias por lascamento e, para o mesmo percurso, porém, com aproximadamente 14,3% do corte em sulcamento, os fenômenos predominantes no desgaste foram abrasão e adesão. O efeito do sulcamento fez com que os fatores tipo de corte e avanço, bem como suas respectivas interações, fossem significativos sobre a energia específica de corte. Os cortes em cheio e corte concordante com avanço de 3 µm/dente proporcionaram condições mais favoráveis para o microfresamento frontal, com melhor acabamento da peça e menores níveis de desgaste da ferramenta de corte. / Micro-machining is one of the processes feasible for generating geometries or parts with precision and complexity regarding dimensions smaller than 1 mm. However, the achievement of enhanced machining performance and product quality requires a prior understanding on the tool-workpiece interface. This research detemined the influence of cutting type and cutting feed on wear (tool), specific cutting force (process) and surface roughness (workpiece) when cutting the ultrafine-grained steel COS AR60 under end milling strategy. Machining tests were performed in a CNC machining centre Romi D600 provided with a high-speed spindle (60kpm) without cutting fluid application. TiAlN coated carbide endmill (Ø 800 μm) was used for straight cut with 60 m/min cutting speed, 160 μm depth of cut and feed per tooth of 3 and 10 μm. Analysis of Variance (ANOVA) with confidence interval of 95% was applied to the three runs of each cutting sets. The results have shown that tool wear levels and tool effective diameter are influenced by tool feed and cutting type. Hence, intermittent impact of tool’s cutting edges into the workpiece (≈11%) during cutting revealed to be the major cause of tool wear when compared to cutting mechanism dominated by ploughing (≈4%). Regarding experimental sets with cutting length of 98,018 m there was a predominance of tool edge chipping over abrasion and adhesion when performing face cutting with ploughing at 4.2%. On the other hand, if ploughing increases to 14.3% the main wear mechanism observed were abrasion and adhesion. Therefore, there was a significant interaction between specific cutting force and the input parameters of feed per tooth and cutting type. As a result, down-milling and channel-milling at the tool feed of 3 μm/tooth leaded to a valuable cutting performance with better workpiece surface roughness and tool wear at low levels.

Made available in DSpace on 2014-06-11T19:24:47Z (GMT). No. of bitstreams: 0 Previous issue date: 2008-01-16Bitstream added on 2014-06-13T20:13:05Z : No. of bitstreams: 1 lanconi_pn_me_bauru.pdf: 2184096 bytes, checksum: bd505129ead7cc5f753979f6f1881a5d (MD5) / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / Os processos de usinagem são de extrema importância no ramo de indústria metalúrgica, uma vez que quase todas as peças de metais em que se exige uma alta precisão e qualidade de acabamento são produzidas por meio destes processos. Dentre os processos de usinagem destaca-se o processo de retificação, por sua precisão e bom acabamento. É essencial que se conheça bem este processo, já que por ser a última etapa da manufatura, qualquer problema compromente a peça e perde-se o trabalho realizado em todas as etapas anteriores. O presente trabalho visa um estudo comparativo entre a força de corte na retificação medida com um dinamômetro piezelétrico e a potência elétrica do motor que aciona o rebolo. A força de corte é reconhecida como sendo a principal variável de estudos dos processos de usinagem. Tradicionalmente a força de corte é tomada por meio de um dinamômetro, porém este é um dispositivo relativamente caro e de difícil montagem. Usualmente, a força no processo de retificação é tomada por meio de um sensor de corrente, obtendo-se um sinal analógico proporcional à potência consumida pelo motor. Entretanto, esta potência não corresponde à potência mecânica utilizada no corte, e, portanto, imprecisões ocorrem. Neste trabalho, os sinais de potências elétricas e força de corte foram coletados com alta taxa de aquisição, com variações de profundidade de corte e da frequência do motor que aciona o rebolo. Os resultados obtidos mostram que os sinais de potência elétrica do motor que aciona o rebolo sempre foram proporcionais aos sinais de força de corte. Desta forma, é possível o dinamômetro na retificação por sensores de corrente e tensão, com resultados confiáveis. / The machining processes are of great importance in the metallurgical industry, since all the metal workpieces demanding high precision and finishing quality are produced through these processes. Among the machining processes the grinding process can be highlighted by its precision and superior finishing. As being the last manufacturing stage, it is very important to have sound knowledge of the grinding process because minor problems can jeopardize the ground part, and then all the previous manufacturing operations will also be lost. This work aims at comparing the cutting force between the one measured through a piezoelectric dynamometer and that one measured by electrical power of the induction motor that drives the grinding wheel. The cutting force is acknowledged as being the most important variable for studying the machining processes. Traditionally, the cutting force is taken by a piezoelectric dynamometer, which is relatively expensive equipment besides requiring a nontrivial setup. Generally, the cutting force in the grinding process is taken by a Hall Effect current sensor to produce an analog signal proportional to the power consumed by the electric motor. However, that power does not correspond to the mechanical power used to grind, and thus imprecision takes place. In this work, the electric power and cutting force were collected by using a high samplinf the rate acquisition for several cutting depths and two electrical frequencies to drives the induction motor. The results showed the electric power signals behaved, in general, proportional to the cutting force measured by the dynamometer. Thus, the Hall Effect curret and voltage sensors can be replaced by dynamometer in the grinding process with reliable results.

This thesis presents a multi-physics-based approach to the design and analysis of smart cutting tools for emerging industrial requirements, within an innovative design process. The design process is in stages according to design specifications and requires analysis, conceptual design, detailed design, prototype production and service testing. The research presented in the thesis follows the design process but focuses on the detailed design of the smart turning tool, including mechanical design, electrical wiring and sensor circuitry, embedded algorithms development, and multi-physics-based simulation for the tool system integration, design analysis and optimisation. The thesis includes the introduction of the research background, a critical literature review of the research topic, a multi-physics-based design and analysis of the smart cutting tool, a mechanical structural detail design of the prototype smart turning tool, the electrical system design focusing on cutting force measurement and embedded wireless communication features, and the final experimental testing and calibration of the smart cutting tool. The contributions to knowledge are highlighted in the conclusions chapter towards the end of the thesis. The research proposes multi-physics-based design and analysis concepts for a smart turning tool, which can measure the cutting forces on a 0.1 N scale and can also be used to monitor the tool condition, particularly for ultraprecision and micro-machining purposes. The smart turning tool is a sensored tool, constructed with wireless and plug-and-produce features. The tool design modelling and simulation was undertaken within a multi-physics modelling and analysis environment-based on COMSOL. This integrates the piezoelectric physics with mechanical structural design and radio frequency electronic communications of cutting force signals. The multi-physics simulation method takes account of all design-mechanics-physics-electronics analysis and transformations simultaneously within one computational environment, including FEA analysis, modal analysis, structural deformation, lead piezoelectric effect and wireless data/signal simulation. With the multi-physics simulation developed, the integrated design of the smart turning tool and its performance can be physically analysed and optimised in a virtual environment. The tool design process follows the total design methodology, which can be strictly executed in several design stages. Both mechanical and electrical design of the smart cutting tool are embodied into the tool detail design. The tool mechanical structure is systematically built from the selection of the tool material, through the structure analysis and further progressed with static force – strain/stress transformation, equivalent force measurement and calibration. The electrical circuitry was systematically developed from developing the customised charge amplifier, detail design of the main circuitry and coding development procedure, preliminary PCB fabrication and multi-sensor port PCB development, as well as the real-time cutting force monitoring programming and interface coding. The experiment calibrations and cutting trials with the tool system are also designed in light of the total design methodology. The experiment procedure for using the smart turning tool is further presented in two different sections. The thesis concludes with a further discussion on the main research findings, which are further supported by the highlighted contributions to knowledge and recommendations for future work.

Nowadays technology development places increasing demands on miniature and micro components and products, and micro-milling is one of the most flexible machining processes in manufacturing 3D structures and complex structured surfaces. A thorough and scientific understanding on fundamentals of the micro-milling process is essential for applying it in an industrial scale. Therefore, in-depth scientific understanding of the micro-cutting mechanics is critical, particularly on size effect, minimum chip thickness, chip formation, tool wear and cutting temperature, etc. so as to fulfil the gap between fundamentals and industrial scale applications. Therefore, three key fundamental research topics are determined for this research, and a comprehensive study on those topics is conducted by means of modeling, simulation, experiments. The topics include chip formation process in micro-milling, novel cutting force modeling in multiscale and study on the tool wear and process monitoring. The investigation into chip formation process in micro-milling consists of three stages; the micro-cutting process is firstly simulated by means of FEA with a primary focus on finding the minimum chip thickness for different tool/material pair and explaining the size effect; the simulation results are then validated by conducting micro-cutting experiment on the ultra-precision lathe. Experiments are carried out on aluminium 6082-T6 with both natural diamond and tungsten carbide tool. By knowing the minimum chip thickness for different tool/material pair, the chip formation process is investigated by performing comparative study by using the diamond and tungsten carbide micro-milling tools. As the minimum chip thickness for diamond micro-milling tool is smaller than that for tungsten carbide tool compared to nominal chip thickness, MCT is ignored in diamond micro-milling. Thus the comparative study is conducted by utilizing both tools with perfectly sharpened cutting edge and tools with the rounded cutting edge in micro-milling. The chips are inspected and associated with cutting force variations in the micro-milling process. The findings are further consolidated by comparing with research results by other researchers. The cutting force modeling is developed in three different aspects, e.g. cutting force on the unit length or area and cutting force on the unit volume in order to better understand the micro-cutting mechanics in aspects of size effect, tool wear mechanism and the cutting energy consumption. The mathematical modeling firstly starts with a novel instantaneous chip thickness algorithm, in which the instantaneous chip thickness is computed by taking account of the change of tool geometry brought about by the tool runout; then the collected cutting forces are utilized to calibrate the model coefficients. For accurate measurement on cutting forces, the Kalman Filter technique is employed to compensate the distortion of the measured cutting force. Model calibration is implemented using least-square method. The proposed cutting force model is then applied in micro-milling to represent the conditions of tool wear and the cutting energy consumption. Further study on the surface generation simulation is based on force model and its comparison with the machined surface is also performed. Cutting experiments using the new tungsten carbide tool are carried out and the tool wear is monitored offline at different machining stages. The dominant tool wear types are characterised. Tool wear is investigated by mainly analysing cutting force at different tool wear status. Frequency analysis by Fourier Transform and Wavelet Transform are carried out on the force signals, and features closely related to the tool wear status are identified and extracted. The potential of applying these features to monitoring the tool wear process is then discussed. Experimental studies to machine the structured surface and nano-metric level surface roughness are presented, the machining efficiency, dimensional accuracy and tool-path strategies are optimised so as to achieve the desired outcomes. Moreover, investigation on cutting temperature in micro-cutting is also studied to some extent by means of simulation; the influence of cutting edge radius on cutting temperature is particularly investigated. Investigation on above aspects provides systematic exploration into the micro-milling process and can contribute substantially to future micro-milling applications.