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1

Intelligent diagnosis and fault prediction of rock breaking process in milling machines based on big data analysis

Wang Jingde, Duan Jian, Sun Qingsong, Han Lu, Tang Jian, Li Jian

Diagnostyka

|

2026

|

Vol. 27, No. 1

art. no. 2026105

EN

This study develops an intelligent method for diagnosing and predicting disc cutter deflection wear faults during rock excavation processes. The proposed method integrates wavelet time-frequency graph encoding with an Inception-Bidirectional Gated Recurrent Unit (Bi-GRU) model through big data analysis techniques. The approach utilizes large-scale vibration signal data to effectively extract time-frequency characteristics of non-stationary signals through wavelet time-frequency graphs, enhancing the model's fault identification capability under complex working conditions. The one-dimensional vibration signal is mapped into a two-dimensional time-frequency graph and input into the Inception-BiGRU model. The spatial features are extracted by using the multi-scale convolution of the Inception module. Meanwhile, the dynamic evolution law is captured by combining the Bi-GRU bidirectional time series modeling to achieve the deep integration of spatial-temporal features. The Inception-BiGRU model demonstrates excellent robustness in multi-condition tests, maintaining a diagnostic accuracy consistently exceeding 98% and reaching a maximum of 99.35%. In multi-class fault identification, the accuracy for normal and severely deflected cutters reaches 99%. Meanwhile, minor misjudgments occur in cases of mild and moderate deflection, with overall identification precision exceeding 97%. A comparative evaluation against various encoding methods and traditional algorithms demonstrates that the Inception-BiGRU model outperforms baseline models in both accuracy and stability, achieving an average accuracy of 98.63% with a variance of only 0.03. The proposed model improves average accuracy by 1.84% and reduces variance by 50% compared to baseline models. The research results verify the effectiveness and engineering application potential of the proposed method in diagnosing and predicting disc cutter faults. This study provides technical support for advancing the intelligent operation and maintenance of milling machines while offering a feasible path for future multimodal sensor fusion and early fault warning.

2

Finite element analysis of the eigenfrequencies of milling machine support structure

Ciemierkiewicz Radosław, Ładecki Bogusław

Technical Sciences / University of Warmia and Mazury in Olsztyn

|

2025

|

Vol. 28

199--213

EN

The publication concerns the selection of dimensions for two support structure models of a woodworking spindle moulder, based on the results of finite element analyses: static structural and modal. Using the ANSYS Workbench software, a linear-elastic material behavior was assumed, and preliminary models of the milling machine frame and housing were analyzed, each assigned a different material – structural steel (S235JR) and gray cast iron (EN-GJL-250), respectively. After completing the Design and Analysis of Computer Experiments stage, optimization was carried out using ANSYS Workbench algorithms: the Response Surface Method and the Direct Optimization Method. As a result, the optimal geometric dimensions of the milling machine’s support structures were identified, satisfying both strength and modal criteria.

3

Innovative Design and Machining Verification of a Dual-Axis Swivel Table for a Milling Machine

Lin Wei-Zhu, Xiao Jian-Xuan, Lin Yung-Chih, Chang Bo-Wei, Hung Jui-Pin

Advances in Science and Technology. Research Journal

|

2024

|

Vol. 18, no. 1

306--319

EN

This study was aimed to develop a dual-axis rotary table for small and medium-sized five-axis milling machines. The rotation and tilting axis of swivel table were respectively driven by servo motor with gear reducer to achieve low speed, high torque, high rigidity and high precision machining capability. Essentially, the dynamic interaction between the work piece and the tool in the cutting process is an important factor that affects the machining performance, which also implies that the structural characteristics of the rotary table with the swiveling angle will affect the cutting performance of the five-axis machine. Therefore, at the design stage of a five-axis machine tool, it is a prerequisite to evaluate change of dynamic characteristics of the rotary module within the desired feeding range. To this purpose, this study employed the finite element method to analyze the dynamic characteristics of the rotary table under different configurations. In order to evaluate the application feasibility of the dual axis module on a milling machine, ISO S-shaped machining tests were carried out. Meanwhile, considering the influence of machining vibration on the surface quality of the work piece, the vibration induced at spindle tool and rotary table were assessed for comparisons and used to evaluate the variation of machining vibration with the milling cycles. Based on various experimental results, it is confirmed that the proposed dual-axis rotary table has good structural dynamic characteristics with stable vibration features during a small batch production tests. Current results clearly demonstrate the potential and capability of the proposed dual axis rotary table in practical application and commercialization.

4

Study on the influence of joint dip angle and spacing on rock fragmentation by TBM double disc cutters

Kang Yiqiang, Yang Renshu, Yang Liyun, Li Yougliang, Yao Man, Gu Shirui

Archives of Civil and Mechanical Engineering

|

2023

|

Vol. 23, no. 4

art. e222, 1--15

EN

Tunnel boring machines’ construction efficiency is significantly affected by the formation of joints. Indentation tests were performed to explore the influence of joints on rock fragmentation by double cutters on a gray sandstone. The process of rock fragmentation was captured by the digital image correlation method. Simulations based on the cohesive element with zero thickness were then conducted to simulate the failure process and evolution of jointed rock under the action of double cutters. A mechanical model is established to deduce the stress evolution in a rock mass by double disc cutters with different penetration depths. The action mechanism and mechanical influence of joints on rock fragmentation were determined. The results show that, under the action of double cutters, the rock with joints is more ready broken than the intact rock mass. The joint acts as a weak interface in the rock mass. Finally, the rock mass is destroyed along the vertical joint, forming rock slag with the joint as the boundary. When the joint dip angle is about 30°, the interaction force between the rock mass and the cutter is low, and the rock fragmentation efficiency is high. And the spacing of joints is also a key factor in the rock-breaking efficiency of double cutters.

5

Effect of Friction Machining on Low Carbon Steel with Titanium Traces in terms of Surface Hardening

Sheikh Ali R.

Archives of Foundry Engineering

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2022

|

Vol. 22, iss. 4

41--46

EN

This work is an experimental study of thermo-mechanical surface hardening of mild steel with trace elements like titanium in negligible concentrations. This is somewhat an advanced technique used to harden steel surface which can be hardened in many typical ways. The concept is combining the thermal as well as mechanical technique to attain better results. It is quite obvious that mechanical refers to the compressive loading during machining and thermal refers to producing heat on the surface of work piece. The ideal conditions are when the heat produced is enough to achieve austenite and then subsequent quick cooling helps in the formation of marten site, which is metallurgically the most highly strong phase of steel, in terms of hardness. The coolant used preferably is the emulsified oil which flows on the surface during machining with variable rate of flow as the optimum effect is. This process hardens the surface of steel and increases its resistance against wear and abrasion. Preference is to achieve surface hardening using the conventional equipment so that operational cost is kept low and better results are attained. This technique has been quite successful in the laboratory. It can be termed as friction hardening. Some improvements in the process scheme and working environment can be made to get better results.

6

Increasing the resource of milling cutters used to process the locomotive wheelsets. Part 2: Study of stressed-deformed state

Sładkowski Aleksander, Proydak Yuriy, Ruban Vladislav

Transport Problems

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2020

|

T. 15, z. 3

139--151

EN

The article deals with the stress-strain state of the cutters used in the mills of a new design for the restoration of the working surfaces of locomotive wheels. A comparative analysis of stresses in the cutters was carried out using the finite element method, which showed a significant advantage of the new technical solution, the novelty of which is confirmed by the patent.

7

Drugi zębnik – budowa i montaż w obrabiarce

Sawicki Tadeusz

Napędy i Sterowanie

|

2019

|

R. 21, nr 6

76--77

PL

Obecnie w przemyśle maszynowym pracują nowoczesne obrabiarki, które przemieszczane są po prowadnicach za pomocą mechanizmów kulowych. Mechanizmy te są drogie i skomplikowane w montażu obrabiarki, szczególnie gdy dotyczy to przejazdu po poziomych długich prowadnicach.

EN

A lot of horizontal boring mills moving on horizontal guide ways using traditional solution type toothed bar and pinion still work in the machine industry. This kind of drive shows errors in positioning caused by clearance in meshing between teeth of toothed bar and pinion. The existing clearance increases with the working time of the machine as a result of wear of the parts mating with each other. Inter-teeth clearance has a negative effect on the accuracy of the workpiece being machined. An effective way to improve the positioning of the machine while driving on the guides is to mount the second pinion to the drive. The principle of the second pinion operation is so that if the first pinion has contact with the tooth of the toothed bar on one side, the second pinion always contacts the tooth of the toothed bar on the other side. This arrangement of both pinions eliminates the negative impact of the inter-teeth clearance, and thus contributes to improving the accuracy of the machine tool.

8

Badania wstępne procesu szlifowania czopu wału na frezarce czteroosiowej

Nowakowski Ł., Miko E., Skrzyniarz M.

Mechanik

|

2018

|

R. 91, nr 8-9

744--746

PL

W artykule przedstawiono wyniki badań wstępnych procesu szlifowania czopu wału na czteroosiowej frezarce AVIA VMC800. Te badania są wprowadzeniem do opracowania procesu szlifowania czołowego czopów wałów korbowych silników okrętowych. Przeprowadzono pomiary wybranych błędów kształtu szlifowanego czołowo czopu.

EN

The article presents the results of preliminary tests of the shaft grinding process on a 4-axis AVIA VMC800 milling machine. The carried out tests are a preparation for the development of the face grinding process of a crankshaft pivots of ship engines. Measurements of selected shape errors of the face-ground journal were carried out in the paper.

9

Budowa i eksploatacja frezarek drogowych

Stawowiak M.

Magazyn Autostrady

|

2018

|

Nr 10

74--87

PL

W artykule opisano poszczególne podzespoły, z których składa się frezarka drogowa. Ponadto w wielu miejscach autor niniejszego artykułu przytoczył sporo przydatnych informacji związanych z eksploatacją oraz zasadami BHP, niezbędnymi przy obsłudze i użytkowaniu frezarek drogowych, a także podał zasady organizacji pracy frezarek na placu budowy. Artykuł zakończony jest podsumowaniem, w którym zamieszczono informacje związane z procesem frezowania.

EN

The paper describes the individual components that make up a road milling machine. Moreover, the author of this article has repeatedly quoted a lot of useful information related to the operation as well as health and safety rules necessary for maintaining and using road milling machines, and also has presented rules for the organization of milling machines operation at a construction site. The article concludes with a summary, which contains information related to the milling process.

10

LEAN manufacturing process planning for 5 AXES CNC driven milling machine

Bodzás S., Krakkó B.

Journal of Technology and Exploitation in Mechanical Engineering

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2018

|

Vol. 4, nr 1

10--28

EN

The aim of this publication is to determine the OEE (Overall Equipment Efficiency) indicator for 5 axes milling machine found at Diehl Aircabin Hungary Ltd. for the present and future state. Based on this value, the utilization of the machine for the given production amount can be calculated. With the optimal choice of the right production parameters (the number of cuts, feeding, depth of cut, etc.) greater productivity can be achieved i.e. the machine main time (time of cutting) will be less. The possibilities of the reduction of the machine time will be analysed and calculated. Setting of the appropriate technological parameters the machine main time could be decreased. The calculation of the machine main time will be determined for the most frequent manufacturing technologies.

11

Ocena dokładności wymiarowo-kształtowej otworów wierconych wiertłami składanymi

Nowakowski Ł., Miko E., Skrzyniarz M.

Mechanik

|

2016

|

R. 89, nr 8-9

1200--1201

PL

W artykule opisano ocenę dokładności wymiarowo-kształtowej otworów wierconych wiertłami składanymi z zastosowaniem różnych sposobów doprowadzenia cieczy chłodząco-smarującej.

EN

The article describes evaluation of accuracy dimensionally shaped holes drilled by indexable insert drill using different modes of administration of cutting fluid.

12

Pomiary odchyleń kątowych stołu pionowego centrum frezarskiego AVIA VMC 800

Maj P., Miko E.

Mechanik

|

2015

|

R. 88, nr 8-9CD2

586--595

PL

Celem artykułu jest przedstawienie metody pomiarów przemieszczeń kątowych stołu obrabiarki sterowanej numerycznie AVIA VMC 800. Stół obrabiarki został tak zaprogramowany, aby realizował przemieszczenia liniowe wzdłuż osi X i Y. Do pomiarów odchyleń kątowych przemieszczeń stołu posłużył interferometr laserowy XL80 firmy Renishaw.

EN

The goal of the article is to present the measurement method of angular displacements of the table of the AVIA VMC 800 numerical control machine tool. The machine table was programmed for implementing linear displacements along the X and Y axis. For measurements of angular deflections of the table displacements, a Renishaw XL80 laser interferometer was used.

13

Prototypowa mobilna frezarka CNC dla pododdziałów remontowych Sił Zbrojnych RP

Jackowski A., Krasoń W.

Mechanik

|

2014

|

R. 87 nr 10

794--795

PL

Obrabiarka to maszyna do kształtowania materiałów poprzez cięcie, wiercenie, szlifowanie lub inne rodzaje deformacji. Skomputeryzowane sterowanie numeryczne (CNC) wspiera ten proces, dzięki czemu jest on szybszy, łatwiejszy i bardziej wydajny. Nowoczesne pole walki wymaga terminowego prowadzenia obsługi technicznej, konserwacji i napraw. Wojskowe obrabiarki nie są przystosowane do produkcji precyzyjnych elementów sprzętu wojskowego. Przedstawiono wymagania dla frezarki przeznaczonej do stosowania w warunkach stacjonarnych oraz jej wstępny projekt. Optymalne rozwiązanie powstało z wykorzystaniem powszechnie dostępnych podzespołów. Opracowane zostały schematy konstrukcyjne, a także obliczono przekroje profili narażonych na odkształcenia. Projekt został zrealizowany w programie Autodesk Inventor 2013 Professional, który umożliwia analizę MES przemieszczeń i naprężeń wynikających z zastosowanych sił.

EN

A machine tool is the machine for shaping materials, usually by cutting, boring, grinding or perhaps by other methods of deformation. Computerized Numeral Control (CNC) is provided to support this process, making it faster, easier and more efficient. Modern battlefield requires technical services, maintenance and repairs to be timely carried out. Military machine tools have not been designed to manufacture precise components for military equipment. The paper presents the requirements for milling machine to be used under stationary conditions complete with its preliminary design drawings. For the presented optimum solution readily available components were selected. Design diagrams were developed and the profiles exposed to deflection significant structural were strength calculated. The project has been carried out using Autodesk Inventor 2013 Professional, which makes it possible to submit the stress and strain values resulting from the applied forces to FE analysis.

14

Virtual machines in education – CNC milling machine with sinumerik 840D control system

Zagórski I., Barszcz M.

Advances in Science and Technology. Research Journal

|

2014

|

Vol. 8, nr 24

32--37

EN

Machining process nowadays could not be conducted without its inseparable element: cutting edge and frequently numerically controlled milling machines. Milling and lathe machining centres comprise standard equipment in many companies of the machinery industry, e.g. automotive or aircraft. It is for that reason that tertiary education should account for this rising demand. This entails the introduction into the curricula the forms which enable visualisation of machining, milling process and virtual production as well as virtual machining centres simulation. Siemens Virtual Machine (Virtual Workshop) sets an example of such software, whose high functionality offers a range of learning experience, such as: learning the design of machine tools, their configuration, basic operation functions as well as basics of CNC.

15

Koncepcja infrastruktury naukowo-badawczej obrabiarek sterowanych numerycznie

Miko E., Nowakowski Ł.

Mechanik

|

2013

|

R. 86, nr 4

284--289

PL

Przedstawiono wybrane przykłady konstrukcji obrabiarek CNC oraz metody ich badania. Trendy w konstrukcji obrabiarek zostały omówione na przykładzie tokarek, frezarek i szlifierki narzędziowej. Metody badania i kalibracji obrabiarek CNC zostały opisane na przykładzie systemu laserowego XL-80, teleskopowego pręta kinematycznego kulkowego typu ballbar oraz przedmiotu próbnego.

EN

The paper presents some examples of CNC machine tools design, construction and methods of testing their accuracy. Trends in the machine tools design are presented on the example of lathe, milling and grinding machines. Three different methods for measuring CNC machine tool accuracy a XL-80 laser measurement system, a ballbar system and last one by measuring test workpieces were described.

16

Modułowe podejście do projektowania frezarek stołowych sterowanych numerycznie

Kuzniecow J., Stepanienkov A., Olejnik J.

Zeszyty Naukowe Politechniki Rzeszowskiej. Mechanika

|

2012

|

z. 84[284], nr 1

51-60

17

Wpływ eksploatacyjnego zużycia łożysk wrzeciona frezarki sterowanej numerycznie na niepewność pomiaru sondą inspekcyjną

Jacniacka E., Semotiuk L.

Przegląd Mechaniczny

|

2012

|

nr 3

22-28

PL

Wykorzystanie sond inspekcyjnych w pomiarach na obrabiarkach sterowanych numerycznie staje się coraz bardziej powszechne. Jednym z głównych czynników mającym wpływ na niedokładność pomiaru przedmiotów obrabianych jest dokładność geometryczna obrabiarki. Eksploatacja obrabiarek prowadzi do zużywania się jej podzespołów, ich remontów a nawet wymiany na nowe, co może mieć wpływ na zmianę charakterystyki metrologicznej wewnątrzobrabiarkowych systemów pomiarowych. Niniejszy artykuł ma na celu analizę jednoosiowej niepewności pomiaru przed i po wymianie łożysk wrzeciona pionowego centrum obróbkowego FV-580A wyposażonego w przedmiotową sondę pomiarową OMP 60.

EN

The use of inspection probes in measurements on CNC machine tools is becoming more common. One of the main factors affecting the uncertainty of measurement of workpieces is the geometric accuracy of machine tools. Using of machine tools leads to components wear, repair or even replacement by new ones, which can affect the change in metrological characteristics of intra-machining measuring systems. The aim of the paper was analysis of uniaxial measurement uncertainty before and after replacing bearings in vertical spindle of machining center FV-580A equipped with the OMP60 probe.

18

Wpływ konstrukcji obrabiarki na dokładność wykonania przedmiotu próbnego

Nowakowski Ł., Miko E.

Pomiary Automatyka Kontrola

|

2012

|

R. 58, nr 1

123-125

PL

W pracy przedstawiono wyniki badań doświadczalnych obróbki przedmiotów próbnych, obrobionych na sterowanych numerycznie pionowych centrach frezarskich AVIA VMC 800, HERMLE B300, DMG DMU 50 wyposażonych w sterowanie HEIDENHAIN iTNC530. Po wykonaniu obróbki przedmioty próbne zostały zmierzone na współrzędnościowej maszynie pomiarowej Contura G2 firmy ZEISS. Analizie została poddana dokładność wymiarowo-kształtowa wykonanego przedmiotu próbnego w odniesieniu do idealnego modelu opisanego w programie obróbkowym.

EN

This study analyses the accuracy of a CNC machine tool by measuring test workpieces. The measurement information enables correction of the CNC program and machining process and, accord-ingly, more efficient use of the machine tool as well as higher accuracy of the final products. The tests were conducted at the Laboratory of CNC Machine Tools of the Kielce University of Technology. The workpiece geometry was prepared applying the Programming Station iTNC530. Once the CNC machining programs were developed, they were sent to the machine tool controller (HEIDENHAIN 530). The test workpieces were made using three different machine tools AVIA VMC800, HERMLE B300, DMG DMU50. The next stage of testing involved measuring the workpiece geometry after the machining process by using the coordinate measuring machine Contura G2 made by ZEISS company. The tests involved determining the machining errors. It was necessary to establish the differences in the geometry between the test workpieces geometry defined by the machining program and that obtained from measuring with the coordinate measuring machine. The results are presented in tables and diagrams.

19

Skracanie czasu obróbki na frezarkach CNC na podstawie okresowej analizy warunków skrawania

Zalewski A.

Inżynieria Maszyn

|

2012

|

R. 17, z. 2

50-61

PL

Frezowanie tej samej części można realizować różnymi narzędziami, z różnymi parametrami skrawania czy przy użyciu różnych strategii ruchu narzędzia. W każdym z tych przypadków, można uzyskać inny czas i inne warunki obróbki. Oba czynniki wpływają na koszt i efektywność realizacji zlecenia. W artykule zaproponowano wykorzystanie wstępnie zdefiniowanych (predefiniowanych) strategii obróbki (szablonów) do automatycznej oceny różnych wersji realizacji tego samego zabiegu obróbkowego. Zastosowano nowoczesne techniki symulacyjne w programie CAM (Catia) oraz syntezę danych (Excel), co pozwoliło w konkretnym przypadku na odpowiedź na pytania: należy zwiększać promieniową czy osiową głębokość skrawania? Frezować z dużym przekrojem warstwy skrawanej czy zastosować małe ap i ae, ale za to większą prędkość posuwu vf?

EN

Milling of the same part can be using various tools, different cutting parameters and different tool path strategies. In any case, one can get a different time and machining conditions. Both factors affect the cost and effectiveness of the execution of the order. The article proposes the use of pre-defined machining strategies (templates) for automatic evaluation of different versions of the same machining operation implementation. The use of modern simulation techniques in the CAM (CATIA) and synthesis of data (Excel) which allowed to answer the questions in a particular case: to increase the width or depth of cut? Milling cutter with a large cross-section of cut or use small ap and ae, but a higher feed rate vf?

20

Wyniki porównawczych badań międzylaboratoryjnych na przykładzie pomiarów dokładności i powtarzalności pozycjonowania liniowych osi frezarki sterowanej numerycznie

Majda P., Jastrzębski R.

Przegląd Mechaniczny

|

2011

|

nr 11

17-24

PL

W artykule przedstawiono wyniki międzylaboratoryjnych badań porównawczych przeprowadzonych w marcu 2010 roku w hali montażowej Centrum Badawczo-Konstrukcyjnego Obrabiarek Sp. z o.o. w Pruszkowie z udziałem Laboratorium Badań Maszyn i Urządzeń Mechanicznych Zachodniopomorskiego Uniwersytetu Technologicznego w Szczecinie oraz Laboratorium Badań Hydrauliki Siłowej i Obrabiarek CBKO Sp. z o.o. w Pruszkowie. Przedmiotem badań były pomiary dokładności i powtarzalności pozycjonowania trzech osi posuwowych X, Y i Z prototypu centrum frezarskiego FV2. Przedstawiono założenia przyjęte do badań porównawczych, analizę procedur szacowania niepewności pomiaru przez laboratoria oraz wnioski praktyczne będące wynikiem wymiany doświadczeń uzyskanych podczas realizacji badań.

EN

Results of interlaboratory tests conducted in March 2010 in the assembly room of R & D Centre for Machine Tools in Pruszkow with the participation of Testing Laboratory of Mechanical Machines and Devices of West Pomeranian University of Technology in Szczecin and Testing Laboratory of Force Hydraulics and Machine Tools CBKO in Pruszkow were presented. Accuracy and repeatability of measurements of three feed axis X, Vand Zof FV2 milling center prototype. Assumptions made for comparative studies, analysis of procedures for estimating measurement uncertainty by laboratories and practical conclusions resulting from the interchange of experience gained during the reali-zation of research were also presented in the paper.