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June 12, 2026Procedia CIRPOpen Access

Process Monitoring Challenges in Five-axis Milling of Thin-walled Parts: An Experimental Perspective

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Authors

LBLele BaiNVNagore VillarrazoJWJun Wang

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Overview

Experimental investigation reveals key challenges for real-time process monitoring in thin-walled components, highlighting tool wear dynamics and chatter effects.

Key Points

  • The research aims to explore the cutting behavior of thin-walled parts during five-axis milling, focusing on tool tilt angles and part thicknesses.
  • Conducted experiments on the five-axis milling process for thin-walled parts under different tool tilt angles and thicknesses.
  • Measured cutting forces, vibrations, and tool wear accumulation to analyze dynamic interactions.
  • Identified challenges in real-time process monitoring through multi-sensor signal capture.
  • Chatter occurrence increases with larger tilt angles; thicker parts help mitigate chatter effects.
  • Tool wear evolution is masked by chatter and part deflection in both force and vibration signals.
  • Cutting force signals show weaker position-dependency compared to acceleration signals.

Cite This Study

Bai et al. (2026) studied this question.

synapsesocial.com/papers/6a2ba44e8101cf8926f02bcchttps://doi.org/10.1016/j.procir.2026.03.011
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Also Consider

Synapse has enriched 5 closely related papers on similar clinical questions. Consider them for comparative context:

  1. 1Performance Evaluation of Five-Axis CNC Milling via Spindle Current and Vibration Monitoring2026
  2. 2Tool Path Strategies for Efficient Milling of Thin-Wall Features2024 · 5 citations
  3. 3Construction and Analysis of Cutting Force and Stability Prediction Model in CNC Milling Thin-Walled Parts Machining2024
  4. 4Multi-Sensory Tool Holder for Process Force Monitoring and Chatter Detection in Milling2024 · 3 citations
  5. 5Research on modeling and prediction of surface morphology of five-axis milling blades based on coupling of forced vibration and trajectory2026