Tool Run-Out Measurement in Micro Milling.

Area of Science:

• Manufacturing Engineering
• Materials Science
• Mechanical Engineering

Background:

• Micro manufacturing processes are gaining importance for producing small-dimensioned components.
• Tool run-out significantly impacts cutting forces, tool longevity, and surface integrity in micro milling.
• Existing methods for tool run-out measurement in micro-scale operations require improvement for reliability and ease of use.

Purpose of the Study:

• To develop an easy and reliable method for measuring tool run-out specifically in micro milling applications.
• To enable integration of tool run-out measurement into Industry 4.0 adaptive control models for enhanced manufacturing.
• To improve production quality, process stability, and reduce machining costs and tool wear.

Main Methods:

• A novel procedure was developed to deduce tool run-out by analyzing actual tool diameter, channel width, and cutting edge phase.
• Cutting force signals were analyzed to estimate the cutting edge phase, with two approximating functions evaluated for automation.
• Experimental tests were conducted on Ti6Al4V samples using coated micro end mills with varied run-out values.

Main Results:

• The developed procedure successfully estimated tool run-out in micro milling experiments.
• The method demonstrated its capability to provide accurate run-out measurements under varying conditions.
• The analysis of cutting force signals proved effective for automated phase measurement.

Conclusions:

• The proposed method offers a practical and reliable solution for tool run-out measurement in micro milling.
• This technique supports the development of Industry 4.0 strategies for intelligent manufacturing and process optimization.
• Accurate tool run-out measurement is essential for enhancing precision, efficiency, and cost-effectiveness in micro-scale production.