A frequency-based analysis of cutting force for depths of cut identification in peripheral end-milling

Abstract

This paper presents a novel approach to identify both radial and axial depth of cut in 2.5-axis peripheral milling operations using cutting force signals analysed in the frequency domain (i.e., cutting force spectrum). In detail, the method exploits the normalized cutting force spectrum, which is directly obtained through dedicated analytical formulations, to estimate depths of cut. The proposed approach is promising and differs from previous works since it does require nor the cutting force coefficients or cutting force direction neither a dedicated instrumentation. The developed method was numerically and experimentally validated in different cutting conditions. The results obtained show that depths of cut are identifiable with a maximum absolute error less than 0.4 mm, proving that the proposed approach could be a solid foundation for a force based cutting condition monitoring system in peripheral milling.