Journal of Mechanical Science and Technology 35 (4) 2021 DOI 10.

1007/s12206-021-0327-4

Journal of Mechanical Science and Technology 35 (4) 2021

Original Article
DOI 10.1007/s12206-021-0327-4
Optimization of cutting fluid supply based
on the motor current
Keywords:
· Intelligent manufacturing system
Geun Byeong Chae1, Ok Hyun Jo1, Wontaek Song2 and Wonkyun Lee1
· Disturbance observer
· Process monitoring 1 2
School of Mechanical Engineering, Chungnam National University, Daejeon 34134, Korea, School of
· Cutting oil
· Friction estimation
Mechanical Engineering, Yonsei University, Seoul 03759, Korea
· Smart machine tool

Abstract A cutting fluid is commonly used in the milling process to improve the tool life
Correspondence to: and surface quality by cooling the cutting zone and decreasing the friction force. To precisely
Wonkyun Lee
wklee@cnu.ac.kr supply the cutting fluid to the cutting zone, the supply direction should be controlled properly by
considering the feed direction and machining type. For example, in the side milling process, it is
effective to inject the cutting fluid perpendicular to the feed direction, whereas, in the slot milling
Citation:
Chae, G. B., Jo, O. H., Song, W., Lee, W. process, the backside of the feed direction is preferable. However, it is difficult to change the
(2021). Optimization of cutting fluid supply supply direction of the cutting fluid during the machining process because a hand-operated
based on the motor current. Journal of cutting fluid supplier is generally applied to conventional machine tools. The multi-directional
Mechanical Science and Technology 35
(4) (2021) 1641~1650. injection of the cutting fluid by using several nozzles constitutes an alternative approach;
http://doi.org/10.1007/s12206-021-0327-4 however, this can lead to the increased consumption of energy during the supply and cooling.
This paper presents an intelligent cutting fluid supplier that can find the optimal supply direction
Received March 3rd, 2020 and control the nozzle position during the machining process. To control the nozzle position
Revised October 20th, 2020 during machining, a three degrees-of-freedom (DOF) robot arm that can be attached to the
Accepted December 9th, 2020 spindle was constructed. The effect of the relative angle between the nozzle and feed direction
on the surface quality was investigated experimentally in order to derive the optimal supply
† Recommended by Editor direction with respect to the feed direction. The optimal supply direction was detected in real-
Hyung Wook Park time based on the feed direction and machining type estimated by the cutting forces in the feed
direction and perpendicular to the feed direction. A disturbance observer was designed to
estimate the cutting force applied to the x- and y-axis based on the table position and torque
command generated by the motion controller. A machining type detection algorithm is
proposed to distinguish the machining types in real-time based on the cutting force. Slot milling
and side milling experiments were conducted to demonstrate the feasibility of the proposed
intelligent cutting fluid supplier. The proposed machining type detection algorithm achieved an
accuracy of 93 % during the machining process.

© The Korean Society of Mechanical
Engineers and Springer-Verlag GmbH
Germany, part of Springer Nature 2021
1. Introduction
A cutting fluid is used in metal cutting processes to improve the surface quality and reduce
tool wear [1]. The cutting fluid reduces the temperature, which is generated in the cutting zone
as a result of friction, and the plastic deformation of the workpiece during chip formation [2].
The cutting fluid also acts as a lubricant that reduces the friction and abrasive wear between
the tool and workpiece. Moreover, the cutting fluid protects the machined surface from corro-
sion and cleans the chips [3]. Many studies have investigated the effect of the cutting fluid on
the surface quality and tool wear in various machining processes. Ebbrell et al. [4] investigated
the effects of the cutting fluid application position on surface quality during the grinding process.
They compared the roughness of the grinded surface for three different positions of the cutting
fluid nozzles, such as the angular position, intermediate position, and tangential position, and
found that the best surface quality was achieved in the angular position because the cutting
fluid was delivered by the adhesion on the grinding wheel. Da Silva et al. [5] analyzed the ef-
fects of the position and pressure of cutting fluid application on tool life and the wear mecha-
nism during the turning process. The crater wear and flank wear were analyzed when the cut-

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 Journal of Mechanical Science and Technology 35 (4) 2021
ting fluid was applied to the workpiece-chip interface and the
chip-tool interface (i.e., the rake face). They reported that the
tool life increased when the cutting fluid was applied to the
chip-tool interface. Cadorin et al. [6] investigated the influence
of the cutting fluid application on machining quality during the
drilling process. The average roughness values measured on
the wall of the holes that were machined by using a normal drill
bit (i.e., external lubrication) and hollow drill bit (i.e., internal
lubrication) were compared. It was reported that the surface
quality improved under the internal lubrication condition, owing
to the reduction of the friction between the tool and the work-
piece in the cutting zone. López de Lacalle et al. [7] investi-
gated the effect of the spray cutting fluids during a high speed
milling process. The influence of the nozzle position, with re-
spect to the feed direction, on tool wear was analyzed by a
computational fluid dynamics (CFD) simulation and machining
experiment. It was concluded that the nozzle position with re-
spect to the feed direction was very important in obtaining the
optimal effect of the spray cutting fluid.
The abovementioned studies have shown that the cutting
fluid application position plays an important role in machining
processes. A supply nozzle should be installed at a proper
position in order to maximize the advantages of the cutting fluid
[8]. However, in the milling process, the relative position be-
tween the supply nozzle and the cutting zone changes during
the machining, in contrast to the abovementioned machining
processes, such as grinding, turning, and drilling with a hollow
drill bit. Therefore, the cutting fluid application position should
be controlled properly in accordance with the feed direction
and the machining types (e.g., slot milling or side milling). For
example, in the side milling process, it is effective to inject the
cutting fluid perpendicular to the feed direction, while the back-
side of the feed direction is better for the slot milling process.
However, it is difficult to change the supply direction of the
cutting fluid because the hand-operated cutting fluid supplier is
generally applied to conventional machine tools. The relative
position between the nozzle and tool is fixed during the entire
machining process. The multi-directional injection of the cutting
fluid by the use of several nozzles is an alternative approach,
but it is inefficient in terms of reducing the consumption of cut-
ting fluid.
The cutting fluid causes environmental pollution because it
contains many types of chemical components such as an ex-
treme-pressure additive, surfactant, bubble suppressant, and
corrosion inhibitor [9]. Therefore, the analysis and minimization
of the environmental burden caused by the cutting fluid is an
important research issue in the manufacturing field [10]. Tan et
al. [11] proposed a multi-object decision making framework
model to reduce the fluid selection in order to minimize the
environmental impact caused by the cutting fluid. A fuzzy as-
sessment method was utilized in order to select the optimal
cutting fluid with consideration to machining quality, cost, and
environmental impact. The feasibility of the proposed method
was demonstrated by applying the model to the hobbing proc-
ess. Debnath et al. [12] reviewed the characteristics of various
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DOI 10.1007/s12206-021-0327-4
cutting fluids for green manufacturing processes. They classi-
fied the cutting fluids into three types, such as oil based, aque-
ous based, and gas based, and analyzed the cooling perform-
ance and ecological problems of each type. Furthermore they
introduced many types of environmentally friendly cutting fluids
with their advantages and chemical properties. Hong and
Broomer [13] applied cryogenic cooling to the metal cutting
process. They analyzed the effect of cryogenic cooling on the
prevention of health hazards and the environmental pollution
caused by the conventional cooling method. The machining
result shows that the machining productivity and tool life im-
proved after the application of cryogenic machining.
From a different viewpoint, various techniques of minimizing
the amount of the cutting fluid used in machining have been
proposed. Minimum quantity lubrication (MQL) is the most
commonly used method of applying the cutting fluid to the cut-
ting zone directly with high pressure in the form of mist [14].
Zhu et al. [15] studied the machining performance and preci-
sion of MQL according to supply parameters and particle size
in minimal lubrication processing (MQL). Senthilkumar et al.
[16] studied the machining quality according to MQL lubrication
conditions (flow rate, feed rate, etc.) in the processing of mod-
ern lightweight materials such as carbon fiber reinforced plas-
tics and titanium alloys. Tazehkandi et al. [17] applied MQL
during the turning process in order to reduce the environmental
problems caused by cutting process. They compared the cut-
ting fluid consumption between MQL and the conventional wet
machining process. Moreover they applied biodegradable
vegetable oil instead of conventional cutting fluid to reduce the
environmental impact. They demonstrated that the MQL with
vegetable oil improves the cooling capacity and machining
quality. Dhar et al. [18] investigated the effect of MQL on tool
wear and surface quality during the turning process. Surface
roughness and flank wear were compared during the turning of
AISI-4340 steel for MQL, in dry and wet machining environ-
ments. It was concluded that MQL machining results in better
tool life and better surface quality in comparison to conven-
tional wet or dry machining. Tawakoli et al. [19] analyzed the
influence of oil mist injection during the MQL grinding process.
The effect of the flow rate and nozzle position on the tangential
force and surface roughness were investigated experimentally.
The best machining performance was observed when the noz-
zle was installed 80 mm away from the machining zone, to-
ward the wheel, and at 10°-20° of inclination with respect to the
workpiece. Attanasio et al. [20] investigated the influence of
MQL on tool wear during the turning process. They compared
the tool life of dry machining and MQL applied toward the rake
and flank faces. They found that the MQL applied toward the
flank face achieved the best tool life, whereas, lubricating the
rake surface did not produce evidence of wear reduction.
Although the MQL machining process can reduce the usage
of the cutting fluid significantly, it causes air pollution, owing to
the harmful oil mist [21]. Apart from MQL, additional techniques
to reduce the usage of the cutting fluid have been proposed.
Varadarajan et al. [22] proposed a minimal cutting fluid applica-
 Journal of Mechanical Science and Technology 35 (4) 2021
tion technique that utilized a thin pulsed jet with high velocity for
the turning process. They demonstrated that the proposed
method exhibited superior machining performance and low
cutting fluid consumption without generating harmful oil mist.
Lee et al. [23] proposed a simulation based machining condi-
tion optimization method for reducing the energy consumption.
In that study, the machining process control method that turned
off the power of the cutting fluid pump was proposed and veri-
fied experimentally. The proposed method can be utilized to
reduce the usage of cutting fluid and the energy consumption
of the fluid pump. Davoodi and Tazehkandi [24] proposed a
machining parameter optimization method for the turning proc-
ess in order to reduce the cutting fluid consumption. The effect
of the machining parameters on the tool tip temperature was
investigated experimentally and was used to determine the
flow rate of the cutting fluid. Appropriate ranges of the machin-
ing condition were proposed for industrial production. Jiang et
al. [25] proposed a model to optimize the machining parame-
ters in order to minimize the consumption of cutting fluid. The
cutting depth, feed rate, cutting speed, and cutting fluid flow
were optimized in order to minimize the process cost, which
includes the operation cost, tool cost, and cutting fluid con-
sumption. The cutting fluid consumption was reduced to 83 %
after the application of the optimization result.
The abovementioned studies can effectively reduce the us-
age of the cutting fluid. However, these studies also deal with
the turning and grinding process by which the relative position
between the supply nozzle and cutting zone is unchanged
during the machining process. The application of the proposed
techniques is not appropriate for the milling process. To solve
this problem, this study proposes an intelligent cutting fluid
supplier for the milling process. The intelligent cutting fluid sup-
plier automatically finds the optimal supply direction and con-
trols the nozzle position during the machining. The influence of
the nozzle position with respect to the feed direction on the
surface quality was investigated experimentally in order to de-
rive the optimal relative angle between the nozzle and feed
direction. The optimal supply direction was derived in real-time
based on the feed direction derived from the part program (G-
code) and the machining type detected by using the cutting
forces in the feed direction and perpendicular to the feed direc-
tion. A disturbance observer was designed in order to estimate
the cutting force applied to the x- and y-axis based on the table
position and torque commands generated by the position con-
troller. To control the nozzle position during machining, a three
degrees-of-freedom (DOF) robot arm that can be attached to
the spindle was constructed. An actual slot milling and side
milling experiment was conducted by using a lab scale three-
axis milling machine in order to demonstrate the feasibility of
the proposed intelligent cutting fluid supplier.
This paper is organized as follows. Sec. 2 presents the de-
sign of the intelligent cutting fluid supplier. The design proce-
dures for the three DOF robot arm with an operation mecha-
nism and cutting force observer are introduced. The detection
algorithm of the optimal supply direction is also introduced in
DOI 10.1007/s12206-021-0327-4
Main Gear
Motor #2
Motor #1
Supply Nozzle Motor #3
Fig. 1. Mechanical design of proposed intelligent cutting fluid supplier.
O x
z
(r, h)
Fig. 2. Side view of intelligent cutting fluid supplier.
this section. Sec. 3 introduces the experimental setup of a lab
scale three axes milling machine with the proposed cutting fluid
supplier. The experimental conditions and algorithm to identify
the model parameters of the cutting force observer are pro-
posed. The experimental results are discussed in Sec. 4 and
the conclusions are drawn in Sec. 5.
2. Design of intelligent cutting fluid sup-
plier
2.1 Mechanical design of cutting fluid supplier
Fig. 1 shows the mechanical design of the proposed intelli-
gent cutting fluid supplier. A stepper motor (motor #1) was
used to control the horizontal angle between the tool and the
supply nozzle by rotating the main gear between the upper and
lower plates. The range of motion of the cutting oil supply mo-
tor can be limited to prevent collisions with other component
parts in the machine tool. In this study, there was a risk of inter-
ference and collision at the mount part connecting the spindle
and the 3-axis feed drive system. To prevent collision, the drive
range of the rotation motor (motor #1) is set to 45 to 315° to
prevent collision with the mount. Several ball casters were
installed to guide the rotating motions of the main gear. The
lower plate was fixed to the upper plate, which was mounted
on a spindle housing. The vertical angle and height of the sup-
ply nozzle were controlled by using two direct current motors
with an integrated angle control unit and gear box (motors #2
and #3). Fig. 2 shows the side view of the intelligent cutting
fluid supplier. r and h represent the horizontal distance be-
tween the center line of the spindle and motor #2, and the ver-
tical distance between the main gear and target point, respec-
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 Journal of Mechanical Science and Technology 35 (4) 2021
tively. l1 and l2 are the length of the link between motors #2
and #3, and the distance between motor #3 and the end of the
supply nozzle, respectively. l3 is the allowance between the
end of the supply nozzle and the target point. α and β are
the angles of motors #2 and #3, respectively. The angle φ
between the spindle and the supply nozzle can be expressed
as follows:
π
φ= −α + β .
2 FInertial = mt 
The relationship between the geometry of the robot arm and
the target point can be expressed based on the cosine laws, as
follows:
r 2 + h 2 = l12 + ( l2 + l3 ) − 2l1 ( l2 + l3 ) cos (π − β ) .
2
The angle of motor #3 can be calculated from the target point
by organizing Eq. (2) as follows:
⎛ r 2 + h 2 − l12 − ( l2 + l3 )2 ⎞
β = π − cos −1 ⎜ ⎟.
⎜ −2l1 ( l2 + l3 ) ⎟ where Fc , Fs , vs , and μv are friction parameters represent-
⎝ ⎠
The angle of motor #2 can be expressed as follows:
α =γ +δ
where
⎛h⎞
γ = tan −1 ⎜ ⎟ ,
r
⎝ ⎠
and
⎛ ( l + l ) sin β ⎞ ⎪⎩ Fthreshold , else
δ = sin −1 ⎜⎜ 2 23 2 ⎟⎟ .
⎝ r +h ⎠
From Eqs. (1)-(6), the target angles of motors #2 and #3
were calculated and applied to the control algorithm. The robot
arm can change from 45 to 315° in the rotational direction de-
pending on the current machining position and type. Therefore,
the rotation motor (motor #1) responsible for rotation was se-
lected in consideration of the gear ratio and the maximum rota-
tion speed of the motor. The rated rotation speed of the se-
lected motor is 315 rpm, and when applying a gear ratio, the
maximum rotational speed in the rotational direction of the
entire machine is about 421.2°/s. Therefore, the device can
optimize the supply position of the robot arm in real time ac-
cording to changing machining types. A microcontroller (Ardu-
ino Uno R3, Arduino) was used to control the three motors of
the intelligent cutting fluid supplier.
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DOI 10.1007/s12206-021-0327-4
2.2 Cutting force observer design
The driving force of the feed drive system was composed of
three components; namely, the inertial force, internal distur-
bances. The inertial force( FInertial ) is the force used to acceler-
ate or decelerate the table system (e.g., ball screw nut, LM
guide blocks, table, fixture, and workpiece) which can be de-
rived as follows:
(1)
x (7)
¨
where mt and x represent the total equivalent mass of the
table system and table acceleration, respectively. The internal
disturbance ( FInternal ) contains the electrical dead zone of the
motor and forces autonomously generated during motion such
as preload, friction force, and structural damping. The forces
(2)
autonomously generated during the motion were modeled as a
classical friction model, as follows [26]:
⎧⎪ ⎛ x ⎞ ⎫⎪
FInternal = μv x + sign ( x ) ⎨ Fc + ( Fs − Fc ) exp ⎜ − ⎟⎟ ⎬ (8)
⎜ v
⎩⎪ ⎝ s ⎠ ⎭⎪
(3)
ing the Coulomb friction, breakaway friction, Stribeck velocity,
and viscous friction coefficient, respectively. All of the parame-
ters were determined experimentally based on the genetic
algorithm [27]. The behaviors of the preload and structural
(4)
damping are reflected in the Coulomb friction and viscous fric-
tion coefficient, respectively. The electrical dead zone is a
nonlinear characteristic caused by the current loss in the elec-
trical circuit of the motor. The input current was negligible and
the driving torque of the motor was zero in the dead zone.
(5)
Therefore, the electrical dead zone can be expressed in force
units, as follows:
⎪⎧ Fdriving , when Fdriving < Fthreshold
Fdeadzone = ⎨ (9)
(6)
where Fdriving is a driving force calculated by the input current.
Fthreshold is a threshold value of the driving force that is calcu-
lated by the input current that begins to generate the actual
driving force. The internal disturbance can be calculated by
summarizing the friction force and the electrical dead zone of
the motor. The external disturbances are unpredictable distur-
bances acting outside of the feed drive system. Under the as-
sumption that there is no other external disturbance except for
the cutting force, the cutting force ( FCutting ) can be derived by
subtracting the inertial force and internal disturbances from the
driving force of the feed drive system, as follows:
2π
FCutting = Tg ⋅ − FInertial − FInternal (10)
Lb
 Journal of Mechanical Science and Technology 35 (4) 2021 DOI 10.1007/s12206-021-0327-4

Position Feedback

Cutting Force(N)
Workpiece
Velocity Feedback Feed
Reference Ffeed direction
position – – Torque
+ Position + Velocity command Motor Actual
Controller Controller Drive Stage
Velocity Fnormal
Motion Controller
Internal disturbance
model
+ – ++ Inertial force (a) Side-up milling
model

Cutting Force Workpiece

Feed
Cutting Force Observer direction
Fnormal
Fig. 3. Flow chart for the correction of the roll forming process design.
Ffeed

where Tg and Lb denote the driving torque and ball screw (b) Side-down milling
lead, respectively. The driving torque is derived by measuring
100

Cutting Force(N)
the torque command voltage generated from the velocity con- Workpiece Feed
Normal Force
Feed Force
troller. Fig. 3 shows the block diagram of the cutting force ob- Ffeed direction 0
server. The cutting force acting on the x- and y-axis is derived
Fnormal -100
by using the cutting force observer, and is then converted to
the feed force (i.e., the cutting force in the feed direction) and
normal force (i.e., the cutting force perpendicular to the feed (c) Slot milling
direction). The velocities of the x- and y-axis are used to de-
Fig. 4. Illustrations and experimentally measured cutting forces of three
termine the feed direction and convert the cutting forces to the
machining types.
feed force and normal force, as follows:

vy vy
Ffeed = cos ⋅ Fx + sin ⋅ Fy
vx vx
vy vy
Fnormal = sin ⋅ Fx − cos ⋅ Fy .
vx vx
Ffeed , Fnormal , vx , and v y refer to the feed force, normal
force, and x- and y-directional velocities, respectively.
2.3 Machining type detection algorithm
The machining types of the milling process can be classified
into three types based on the relative position between the tool
and workpiece: side-up, side-down, and slot milling. Figs. 4(a)-
(c) shows the illustrations and experimentally measured cutting
forces of the three machining types. A tool dynamometer
(Dynoware Type 9272, Kistler) was used to measure the cut-
ting force during the machining of Aluminum 6061 by using a
Φ10 flat four flute end-mill. Fig. 4(a) shows the result of the
side-up milling process. The direction of the feed force was
opposite to the feed direction because the tool pushed the
workpiece during the machining process. The direction of the
normal force was perpendicular to the feed direction in the
counter clock-wise (CCW) direction because the tool pulled the
workpiece from the right side. The mean values of the feed and
normal forces during the material removal were calculated as
-66.88 N and -42.07 N, respectively. Fig. 4(b) shows the result
of the side-down milling process. The direction of the feed force
was the same as the feed direction because the tool pulled the
workpiece during the machining process. The direction of the
normal force was perpendicular to the feed direction in the
CCW direction because the tool pushed the workpiece from
the left side. The mean values of the feed and normal forces
(11)
during the material removal were calculated as +16.98 N and
-80.25 N, respectively. The magnitude of the feed force was
(12)
much smaller than that of the side-up milling process because
the relative force in the feed direction between the tool and the
workpiece generated during the feed motion offsets the pulling
force. As shown in Fig. 4(c), in the slot milling process, both the
side-up and the side-down milling processes were conducted
simultaneously. The direction of the feed force was opposite to
the feed direction because the pushing force generated at the
left side of the tool was larger than the pulling force generated
at the right side of the tool. The direction of the normal force
was perpendicular to the feed direction in the CCW direction, in
accordance with the normal forces of the side-down and side-
up milling process. The mean values of the feed and normal
forces during the material removal were calculated as -53.49 N
and -114.7 N, respectively, and were similar to the summation
of the cutting forces in the side-up and side-down milling proc-
esses.
As discussed above, the cutting forces in the feed direction
and perpendicular to the feed direction exhibited different pat-
terns in accordance with the machining type. Fig. 5 shows the
flow chart of the machining type detection algorithm proposed
in this paper. The feed force of the side-down milling had a
positive value, while the side-up and slot milling had negative
values. Therefore, the side-down milling was distinguished
based on the sign of the feed force. However, the signs of the
feed and normal forces of the side-up and slot milling proc-
esses were the same. The side-up and slot milling processes
could be distinguished based on the relative magnitude of the
feed and normal force. In the case of the side-up milling proc-

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 Journal of Mechanical Science and Technology 35 (4) 2021
Yes
? Side-down milling
No
Yes
? Side-up milling
No
Slot milling
Fig. 5. Flow chart of machining type detection algorithm.
ess, the magnitude of the normal force was smaller than that of
the feed force. The relative force perpendicular to the feed
direction between the tool and the workpiece, which was
caused by the feed motion, offset the pulling force. However,
the magnitude of the normal force was larger than that of the
feed force in the slot milling process.
3. Experimental setup
3.1 Experimental setup
Fig. 6 shows an experimental setup of the lab scale three
axes machine tool. The feed drives with a stroke of 150 mm
were equipped with ball screws (BNK1004; diameter: 10 mm;
lead: 4 mm; THK) and LM guides (SSR15XW, THK) were used
as the x- and y-axis. A ball screw (BNK1002; diameter: 10 mm;
lead: 2 mm; THK), with a smaller lead in comparison to the x-
and y-axis, was used for the z-axis in order to deteriorate the
position error caused by the mass of the spindle system. A
urea-based grease (AFA, THK) with a dynamic viscosity of 20
mm2/s was used to lubricate the ball screw and the LM guides.
A permanent magnet synchronous motor (SGM7J, Yaskawa)
with a rated torque of 0.635 Nm driven by a servo drive
(SGD7S, Yaskawa) was utilized to drive each feed drive. A
high-frequency motorized spindle with a rated power of 2.6 kW
(K-SK-2, Kospin) was used in the machining experiment. A
commercial motion controller (Clipper, Delta Tau) was used to
control the feed drive system. A real-time computer (MicroLab-
Box, dSPACE) was utilized to gather the encoder signal of
each axis and derive the optimal nozzle position in real-time
based on the detection algorithm. The torque command signals
for x- and y-axis generated from the motion controller were
captured using analog-to-digital converters of the real-time
computer. The experiment was conducted using a lab-scale 3-
axis machine tool, but the results of this study can be applied
equally to 3-axis machining centers that high-speed and heavy
cutting are constructed.
3.2 Parameter identification
The cutting force observer that was used in this study con-
tained unknown model parameters (i.e., Fthreshold , Fc , Fs , vs ,
and μv ). Fthreshold , which is the threshold value of the driving
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DOI 10.1007/s12206-021-0327-4
Fig. 6. Experimental setup of lab scale three axis machine tool.
force, was derived as 17.5 N by measuring the torque com-
mand when the motor started to rotate. Fc , Fs , vs , and μv
are friction model parameters that reflect the friction character-
istics, including the behavior of the preload and structural
damping. The friction model parameters were difficult to derive
mathematically because the rolling contact components, such
as the ball screw and LM guides, generated complex behavior
[28]. Moreover, the friction model parameters depended on the
assembly states and operating conditions, such as temperature
and humidity. However, the friction model parameters had to
be determined accurately because the friction force accounted
for large share of total internal disturbances [29]. In this regard,
the friction model parameters were identified based on the
experimentally measured Stribeck curves of the x- and y-axis.
The friction force was measured during the reciprocal motion
with constant velocities in the range of 0.1 mm/s and 15 mm/s.
The average friction torque was calculated from the torque
command generated from the motion controller and converted
to a linear force based on the ball screw lead. We used a ge-
netic algorithm, which is a probability searching algorithm with
globally adaptive optimization, in order to estimate the friction
model parameters from the Stribeck curves [30]. The genetic
algorithm toolbox in MATLAB was used to set the genetic algo-
rithm parameters and derive the optimal solutions that mini-
mized the cost function. The population size, crossover rate,
mutation rate, and generation gap, were set as 20, 0.8, 0.01,
and 1, respectively, for the optimization. Figs. 7(a) and (b)
shows a comparison of the Stribeck curves to those measured
experimentally and estimated based on the identified friction
model parameters. Table 1 lists the identified friction model
parameters.
4. Results and discussion
4.1 Effect of supply direction of cutting fluid
on machining quality
The effect of the supply direction of the cutting fluid on the
side-down milling process was investigated experimentally in
 Journal of Mechanical Science and Technology 35 (4) 2021 DOI 10.1007/s12206-021-0327-4

Table 1. Identified friction model parameters for x- and y-axis.

Symbol x axis y axis Supply nozzle

(units) 0° Feed
65.5 -55.7 43.0 -30.1 Direction
FC (N) 89.9 -75.4 62.6 -50.4
-4 -4 -4 -4
FS (N) 6.9×10 -6.0×10 9.0×10 -9.9×10
3 3 3 3
vS (m/s) 1.5×10 1.3×10 1.3×10 1.8×10 90°
270°
μv (N s/m) 65.5 -55.7 43.0 -30.1

180°
Workpiece
Friction (N)

(a) Nozzle position in the experiment

Side-down milling

Ra (μm)
0.7440

0.4292
(a) x axis 0.5293

0.1241

Supply angle (degree)

(b) Surface roughness in accordance with supply angle

Fig. 8. Effect of cutting fluid supply direction on machining quality.

(b) y axis
Fig. 7. Comparison of Stribeck curves those measured experimentally and
estimated based on identified friction model parameters.
order to determine the optimal nozzle position. The surface
roughness of the machining results was compared when the
supply angle (i.e., relative angle between the feed direction and
nozzle position) was changed. The surface roughness of the
three points of the machined side wall was measured by using
the stylus type two-dimensional surface profiler (IQ, Alphastep).
Fig. 8(a) illustrates the nozzle position in the experiment. Alu-
minum 6061 was machined by using a Φ10 flat four flute end-
mill. The spindle speed and feed rate were set as 2500 RPM
and 0.4 m/min, respectively. Fig. 8(b) is the measured surface
roughness in accordance with the supply angle. The result
shows that the optimal supply angle for the side-down milling
process is 270°. It means that the optimal supply angle for the
side-up milling process is 90°. In the case of the slot milling
process, with a supply angle of 270°, the surface quality of the
side wall under side-up milling area would be poor. Therefore,
a supply angle of 180° is the best condition for the slot milling
process.
4.2 Cutting force measurement
To evaluate the performance of the cutting force observer
the cutting forces in the feed direction and perpendicular to the
feed direction were measured during the milling process. Three
types of machining experiments were carried out in accordance
to the machining types (i.e., side-up, side-down, and slot mill-
ing). An Φ6 flat four flute end-mill was utilized to machine the
Aluminum 6061 with a spindle speed of 6000 RPM and feed
rate of 0.12 m/min. The three processing types defined in this
paper were tested under the same conditions as all other con-
ditions. Fig. 9(a) is an upward cutting experiment, Fig. 9(b) is a
downward cutting experiment, and Fig. 9(c) shows the groove
cutting experiment method. Except for the machining type,

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 Journal of Mechanical Science and Technology 35 (4) 2021 DOI 10.1007/s12206-021-0327-4

50 Feed force
Normal force

-50
SL

SU

SD
(a) Side-up milling
None
0 5 10 15 20
Process Time(s)
(a) Side-up milling

50 Feed force
Normal force

-50
(b) Side-down milling SL

SU

SD

None
0 5 10 15 20 25
Process Time(s)
(b) Side-down milling

(c) Slot milling

Fig. 9. Machining experiment to estimate cutting force using cutting force

observer.

each machining was performed in the same conditions as axial

depth of cut, machining speed, and condition of the tool. The
forces contain some noise in comparison to the cutting forces
measured by the tool dynamometer shown in Fig. 4. The ripple
force caused by the operation of the ball screw, bearings, and
LM guides was contained in the cutting force measured by the
cutting force observer. As mentioned in Sec. 2.3, the feed force
was negative in the side-down milling process and positive in
the side-up and slot milling processes. The relationship be-
tween the feed forces for the three machining types was similar
to the cutting forces measured by the tool dynamometer. How-
ever, the normal forces measured by the cutting force observer
tended to differ from the normal forces measured by the tool
dynamometer. Although the normal force was generated be-
tween the tool and workpiece during the side-up milling proc-
ess, the normal force measured by the cutting force observer
was zero. The x axis feed drive maintained the same position
during the machining in the y direction. In this case the x direc-
tional force (i.e., normal force), which was less than the thresh-
old value of the driving force ( Fthreshold ), could not be measured
by the cutting force observer. However, this characteristic did
not affect the accuracy of the machining type detection.
(c) Slot milling
Fig. 10. Results of detection algorithm for three machining types.
4.3 Machining type detection
The accuracy of the machining type detection algorithm was
verified by applying the algorithm to the cutting forces meas-
ured by the cutting force observer. The counting sort algorithm
was utilized in order to reduce the misjudgment caused by the
noise in the cutting forces. Moreover, the detection result was
recognized when the same result continued for more than 500
times. The graphs in Fig. 10 show the determination result of
the detection algorithm for each machining type. SU, SD, and
SL represent the side-up, side-down, and slot milling process,
respectively. The accuracy of the detection algorithm was 93 %
during the machining process. The accuracy of the processing

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 Journal of Mechanical Science and Technology 35 (4) 2021
situation was determined as the percentage of the total number
of data sets for which the algorithm returned correct answers.
The results revealed that the detection accuracy was de-
creased before and after the machining because of the noise
contained in the cutting force. This problem can be solved by
ignoring the change of the machining type in the idling state
(i.e., except for the machining state). The machining and idling
states were distinguished by using the magnitude of the cutting
force.
5. Conclusion
This study presented an intelligent cutting oil supplier to op-
timize the supply direction of the cutting fluid. The intelligent
cutting oil supplier was composed of a three DOF robot arm to
control the nozzle position and monitoring system in order to
find the optimal nozzle position. The intelligent coolant supply
device is a technology that can be applied to a variety of
equipment by allowing the machining types to be monitored
through current monitoring without the need for additional sen-
sors. A series of experiments were conducted to demonstrate
the performance of the proposed intelligent coolant supplier.
The conclusions drawn from this study can be summarized as
follows.
1) A three-degree-of-freedom robot arm with a control algo-
rithm was constructed to control the nozzle position during
processing.
2) In order to find the optimum nozzle position for the feed di-
rection, the effect of the feed direction on the processing quality
was investigated. The results again confirmed that the optimal
feed angles for the side up, side down and slot milling proc-
esses were 90°, 270° and 180°, respectively, for the feed direc-
tion.
3) The disturbance observer is designed to measure the feed
direction and the cutting force perpendicular to the feed direc-
tion. The performance of the proposed observer was verified
by comparing the derived cutting force with the cutting force
measured with a tool dynamometer.
4) A machining type detection algorithm was proposed to dis-
tinguish the machining type during the machining process
based on the cutting force. The proposed algorithm achieved
93 % accuracy for the three types of processing.
The intelligent cutting fluid supplier can be applied to conven-
tional machine tools without attaching any sensors and modify-
ing the control system. Applying the proposed intelligent cutting
fluid supplier, it is possible to respond to the relative position of
the tool and the workpiece that changes in real time during
machining. In addition, cutting fluid can be accurately supplied
to the cutting zone, which effectively improves machining qual-
ity and tool life. The tool position and cutting condition in milling,
which can be detected through the developed algorithm, can
be applied to the optimization of machine tool parameters in a
3-axis machining center. It can also reduce the use of cutting
oil and reduce environmental pollution by applying minimal
lubrication processing.
DOI 10.1007/s12206-021-0327-4
Acknowledgments
This work was supported in part by Basic Science Research
Program through the National Research Foundation of Korea
(NRF) funded by the Ministry of Science, ICT & Future Plan-
ning (NRF-2019R1F1A1050719) and in part by the Technology
Innovation Program (20012834, Development of Smart CNC
Control System Technology for Manufacturing Equipment)
funded by the Ministry of Trade, Industry & Energy (MOTIE,
Korea).
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Geun Byeong Chae is a Graduate
Student at the School of Mechanical
Engineering, Chungnam National Uni-
versity. His present research interests
include monitoring and control of
machining processes based on
machinine learning.
Ok Hyun Jo is a Graduate Student at
the School of Mechanical Engineering,
Chungnam National University. His
present research interest include
modeling digital twin of machine tools.
Wontaek Song is a Graduate Student at
the School of Mechanical Engineering,
Yonsei University. His present research
interests include modeling and precision
control of feed drive systems.
Wonkyun Lee received his B.S. and
Ph.D. degrees in Mechanical Engi-
neering in 2008 and 2015, respectively,
from Yonsei University, Seoul, South
Korea. He is currently an Assistant
Professor at the School of Mechanical
Engineering, Chungnam National Uni-
versity, since 2016. His research
interests include robotic machining systems, machine learning,
friction compensation control, and machine tool optimization
based on cyber-physical systems.