Abstract:
As advancements continue in precision engineering, the management of complex tribological interactions—specifically friction, progressive tool wear, and thermo-kinematic deviations - remains a critical challenge in achieving precise geometric accuracy and high surface integrity on complex freeform three-dimensional shapes. This research examines the tribological aspects of high-speed surface milling of ductile medium-carbon C45 steel using a comprehensive closed-loop machining framework. To control high friction at the tool-chip interface and to mitigate the formation of built-up edge (BUE), the process was optimized through specific cutting and lubrication strategies. A key innovation of this study is the implementation of an active feedback loop, utilizing advanced macro programming integrated with automated on-machine metrology, which facilitates real-time monitoring and dynamic compensation for progressive tool wear and thermal expansion. The tribological and geometric performance was rigorously evaluated using 3D profilometry, contact surface measurement, and dynamic wear analysis. Experimental data revealed that active wear compensation notably minimized setup uncertainties—from 0.03 mm to 0.003 mm—and preserved highly accurate three-dimensional contours with an average profile deviation of 17 micrometers (ranging from 12 to 20 micrometers). Furthermore, the optimized control of friction and tool kinematics resulted in an exceptional surface roughness (Rz) of 4.37-5.14 µm, nearly eliminating mesh artifacts and reducing the need for manual post-polishing by up to 70%. These findings offer a robust, data-driven method for enhancing surface integrity and extending tool life in smart manufacturing processes that demand continuous, high-precision production.
Keywords:
Tool wear compensation,
Friction control,
Surface integrity,
On-machine metrology,
Freeform surface milling,
C45 steel
Recieved: 06.04.2026,
Revised: 05.05.2026,
Accepted: 02.06.2026
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