Energy Based Cutting Force Model Calibration for Milling

Abstract

Accurate estimation of cutting forces requires that the predictive model be properly calibrated. Calibration typically requires a time consuming process and an expensive force measurement device. In this paper, an energy based process is described for calibrating a force estimation model using motor spindle power. Experimental results for flat and ball end mills are given. The method has been shown to be accurate for estimating forces for a wide variety of cutting conditions. Furthermore, we show how the calibration process can be done either off-line with a quick and simple process, or on-line while cutting in a production process. An additional benefit of the method is that the continuous calibration process can be used to help diagnose tool wear.