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In order to machine a wide variety of materials with a single spindle and setup, a multi-purpose spindle for machine tools has been developed. The spindle achieves both high power/ torque for heavy duty milling operations and higher rotational speed. The developed spindle is equipped with an additional motor at the back of a conventional induction motor driven spindle to assist the induction motor when high milling torque is needed. For high speed operation, the additional motor can be mechanically disengaged and the spindle can be used as a conventional spindle. A Permanent Magnet Synchronous Motor (PMSM) is adopted for the additional motor, because a highly stable milling operation can be realized by utilizing the advantage of the PMSM. As expected, cutting experiments have shown that the material removal rate has been greatly improved with the developed spindle.

The study aims at analyzing the tool utilization by using a real-time machining simulation and investigating the behavior of the parameters which affect the tool wear based on the results of the analysis. In this study, the method of calculation of parameters which are necessary to predict the tool wear by using Z-map based machining simulation is developed. Furthermore, the possibility of estimating the tool wear from the results of the simulation was also examined by performing the real cutting experiments.

The paper deals with the end-milling machinability of α-β titanium alloy (Ti-6AI-4V alloy) by new PCD (Polycrystal-line Diamond) cutting tools at high cutting speeds in order to develop a new technology for a high productivity titanium finishing. The main focus of this paper is on investigating the relationships among cutting conditions, PCD tool materials, and tool wear. It was found that the edge engagement time of cutting tools with titanium workpiece has a great effect on PCD tool wear. Compared to cemented carbide tools, PCD tools have a longer tool life, especially at higher cutting speeds. The geometric shape of cutting edges and tool material greatly influences the performance of PCD tools in cutting titanium alloy.