For instance, ultra-precision and micro machining, with the surface roughness normally at the nanometric scale and features/patterns at the micrometer level, is increasingly and continuously demanded particularly for high precision components and products with improved functionality and performance. Furthermore, for many high value precision machining processes, it is important to use smart cutting tools to carry out the processes in a ‘proactive’ manner, in order to cope with machining dynamics, process variations and complexity. In high precision machining, however, to position the cutting tool with such high accuracy and repeatability is the key and this is normally undertaken in a “passive” manner, i.e., the tool’s position relying on the slideways’ positioning accuracy but without measuring the tool cutting behaviour and process conditions. In modern advanced manufacturing, it is becoming an essential trend for machining components with an ever increasing dimensional/form accuracy and finer surface roughness, even surface functionality requirement. Smart tooling and smart machining have tremendous potential and are drawing attention as one of next generation precision machining technologies particularly in the Industry 4.0 context. Furthermore, implementation techniques are presented focusing on: (a) plug-and-produce design principle and the associated smart control algorithms, (b) piezoelectric film and surface acoustic wave transducers to measure cutting forces in process, (c) critical cutting temperature control in real-time machining, (d) in-process calibration through machining trials, (e) FE-based design and analysis of smart cutting tools, and (f) application exemplars on adaptive smart machining. They are contamination-free machining, machining of tool-wear-prone Si-based infra-red devices and medical applications, high speed micro milling and micro drilling, etc. Implementation and application perspectives of these smart cutting tools are explored and discussed particularly for smart machining against a number of industrial application requirements.
This paper presents some innovative design concepts and, in particular, the development of four types of smart cutting tools, including a force-based smart cutting tool, a temperature-based internally-cooled cutting tool, a fast tool servo (FTS) and smart collets for ultraprecision and micro manufacturing purposes. Smart machining has tremendous potential and is becoming one of new generation high value precision manufacturing technologies in line with the advance of Industry 4.0 concepts.
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