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In this paper, we study the stability of a high speed milling process of nickel superalloys Inconel 713C by methods used in nonlinear dynamics. Stability Lobe Diagram was a result of modal analysis and next verified by recurrence plots, recurrence quantification analysis and classical nonlinear methods. A stability lobes diagram shows the indistinct boundary between chatter-free stable machining and unstable processes. Nevertheless, some recurrence quantification analysis measures give interesting results.

This investigation has designed a tool condition monitoring system (TCM) while milling of Inconel 625 based on sound and vibration signatures. The experiments were carried out based on response surface methodology (RSM) central composite design, design of experiments. The process parameters such as speed, feed, depth of cut and vegetable-based cutting fluids were optimized based on surface roughness, flank wear. It was found that the sound pressure and vibration signatures have the direct relation with flank wear. The statistical features like root mean square, skewness, kurtosis and mean values were extracted from the experimental data. From the designed NN estimator, the cutting tool flank wear was predicted with the mean square error (MSE) of 0.084212.

Robot milling process is an important development direction of robot technology, and the automatic tool path generation method is the key step of it. In this paper, an improved CC route method is presented to generate the tool path based on the geometric development platform of Open Cascade. By adjusting the distance of constrain planes dynamically, the inhomogeneous problem of traditional CC method is avoided and the robot milling precision can be improved. Based on the above, a corresponding CAM system is developed. Tool path of rough and fine milling process for free surfaces can be generated through this system. At last, the feasibility and precision of this method are validated by simulation and experiment.