Prof. Massimiliano Annoni

Politecnico di Milano, Italy

Increasing the milling process sustainability through experiments, simulation and process planning supported by Industry 4.0 tools


Milling is a well-known and versatile process that is spread in many industrial fields to manufacture parts of complex 3D shape made of advanced materials. Parts can be obtained through infinite combinations of process chains involving milling only or other processes depending on the target quality, times and costs. This talk deals with strategies that can be implemented when all of these constraints are pushed to the limit and the milling process must be optimized to achieve a sustainable and competitive performance.

Milling force modelling is a valuable way to have a clear representation of the tool effort and consequently select manufacturing strategies and parameters when parts are too complex or when the first-time-right approach has to be applied to satisfy constraints in customized and small batch productions.

A possible strategy to better calibrate a milling force model and minimise the number of experiments will be presented, then some examples will be made for demonstrating how milling force prediction allows a better milling process planning and a better usage of resources.

A framework can be set-up around milling and other processes for helping manufacturing companies to be competitive in this scenario by exploiting Industry 4.0 tools as digital twins, able to simulate the milling process and all related resources with a high level of accuracy by making use of both nominal data coming from their specs and real data coming from the field.

The role of machine data collection will also be discussed to support the decision-making process and facilitate flexible and zero defect manufacturing.

Some projects using this paradigm will be mentioned in this talk together with some industrial applications.

Massimiliano Annoni


Massimiliano Annoni is Associate Professor in Technologies and Production Systems at the Department of Mechanical Engineering of Politecnico di Milano (PoliMi). He carries out research activities for developing and applying advanced manufacturing operations of milling, micromachining, high precision waterjet machining, extrusion-based additive manufacturing and their combinations in complex and hybrid process chains, with a specific attention to the application of I4.0 tools to manufacturing processes. He is the coordinator of PoliMill, MI_crolab and WJ_Lab laboratories of the Department of Mechanical Engineering of Politecnico di Milano. He is scientific coordinator of WatAJet, a spin-off company of PoliMi dealing with high precision waterjet cutting. He has been the coordinator of various regional projects and he has participated into various European projects, including Marie Skłodowska-Curie Actions (Innovative Training Networks (ITN)). He is author of more than 120 publications on international journals and conference proceedings and he is Associate Editor of Manufacturing Letters and the Journal of Manufacturing Processes (SME).

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