Development of a Novel Modular and Agile Face Machining Technology

A novel face machining technology has been achieved by combining milling and grinding into one operation. The system's ability to control these distinct metal removal processes independently provides a high degree of process agility in terms of metal removal rate, surface finish and part flatness. A physics based model of the combined process has been developed to aid process development. It provides force and deflection values resulting from the unique excitation of milling and grinding together with the dynamics of the machine, fixture and part. The simulations are presently being validated using a prototype machine based on this machining technology.