Virtual milling force monitoring method based on in-process milling force prediction model to eliminate predetermination of cutting coefficients

Abstract

In this study, a virtual milling force monitoring method is proposed for industrial milling process monitoring. For this purpose, a modified instantaneous rigid force model is proposed. Oblique and orthogonal cutting theories are applied in the model to reduce the number of cutting parameters required for milling force prediction. Only the shear angle must be determined in advance for cutting force prediction. In practice, the shear angle can be determined immediately at the start of a milling operation. Based on the shear angle, the milling forces are predicted and can be used instead of the measured milling forces. In addition, in the proposed force model, runout is taken as the difference in the uncut chip thickness between cutting edges. In order to confirm the effectiveness of the proposed force model, a milling experiment was conducted. The predicted milling forces were found to be in agreement with the measured values. These results demonstrate that milling process monitoring can be achieved without conducting experimental milling to determine the required parameters for prediction or installing additional force sensors.