The setting of cutting variables for precision milling of ceramics is important to both the machined surface quality and material removal rate (MRR). This work specifically aims at the performance of corner radius PCD (polycrystalline diamond) end mill in precision milling of zirconia ceramics with relatively big cutting parameters. The characteristics of the cutting zone in precision milling ceramics with corner radius end mill are analyzed. The relationships between the maximum uncut chip thickness (h_max) and the milling parameters including feed per tooth (f_z), axial depth of cut (a_p) and tool corner radius (r_ε) are discussed. Precision milling experiments with exploratory milling parameters that cause uncut chip thickness larger than the critical value were carried out. The material removal mechanism was also analyzed. According to the results, it is advisable to increase f_z appropriately during precision milling ZrO₂ ceramics with corner radius end mill. There is still a chance to obtain ductile processed surface, as long as the brittle failure area is controlled within a certain range. The appropriate increasing of a_p, not only can prevent the brittle damage from affecting the machined surface, but also could increase the MRR. The milling force increases with increasing MRR, but the surface roughness can still be stabilized within a certain range.

Three-axis milling machine tools are widely used in manufacturing enterprises, and they have enormous potential demands for remanufacturing to improve their performance. During remanufacturing a three-axis milling machine tool, the structure needs to be reconstructed, so it is necessary to identify sensitive geometric errors of the remanufactured machine tool. In the traditional sensitive geometric error identification method, complex error modeling and analysis must be conducted. Therefore, professional knowledge is required, and the process of the identification is cumbersome. This paper focused on the quick identification of sensitive geometric errors for remanufacturing of three-axis milling machine tools. Firstly, sensitive geometric errors of a three-axis milling machine tool were identified based on the multi-body system theory and partial differential method. Then, mapping laws between the sensitive geometric errors and the machine tool structure were firstly presented. According to the proposed mapping laws, the sensitive geometric errors can be identified quickly and easily without complex error modeling and analysis. Finally, the simulation and experiment show that the straightness error of milling is improved up to 0.007 mm by compensating the sensitive geometric errors identified by the proposed mapping laws. The table lookup method based on the mapping laws can quickly identify the sensitive geometric errors of three-axis milling machine tools, which is beneficial for the efficiency and precision of remanufacturing of machine tools.

Assembling plays a significant role in the performance of large-scale CNC gear profile grinding machines. An approach in the deviation evaluation of ground tooth surfaces taking into account assembly errors is proposed in this paper. Based on the error transmission chain of the profile grinding system and the conjugate motion relationship between the grinding wheel and the workpiece, the ground tooth surface model including assembly errors was established using the surface envelope method. Then, the effect of assembly errors on deviations of the profile grinding tooth surface was quantitatively analyzed. The optimized distribution of assembly errors and machining verifications were performed on large-scale CNC gear profile grinding machines. The results show that the proposed method is effective at ensuring ground tooth surface deviations for large-scale CNC gear profile grinding machines.