Professor of Mechanical Engineering and Smart Structures, School of Computing Engineering and Mathematics, Western Sydney University, Australia. His research interests cover Industry 4.0, Additive Manufacturing, Advanced Engineering Materials and Structures (Metals and Composites), Multi-scale Modelling of Materials and Structures, Metal Forming and Metal Surface Treatment.
Abstract—Tool eccentricity is considered as the misalignment between the axis of rotation of the spindle and the axis of symmetry of the tool whereas surface roughness is enumerated by the abnormalities in the way of the typical vector of an actual superficial from its superlative form. A small eccentric offset may cause negligible effect in macroscale milling, while in micro-scale milling, it can result in unstable periodic variations in chip load, surface roughness and cutting forces which can cause destruction in the whole machining system and will provide hurdles in the way of fulfilling the customer demands which are actually the product having high dimensional accuracy of the work piece along with high surface finish. In this case study, solution for the decrement of eccentricity and surface roughness value was provided in the form of clamping of spindle, tool holder and milling cutter at different orientations. It was proved through performing numerous experiments on CNC vertical milling by measuring the geometric imperfections of all the machining elements at different orientations with Swiss SYLVAC dial gauge and 24-test cuts were performed with different cutters by making combinations of machining elements at different orientations and after every test-cut surface roughness value was measured MarSurf PS1. Both indicated that orientations affects the eccentricity and surface roughness highly and through this technique customer demands can be fulfilled in a better way.
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