A study of computing accuracy of calibrating cutting force coefficients and run-out parameters in flat-end milling

Abstract

It is well known that the presence of cutter run-out has a significant effect upon the instantaneous uncut chip thickness through redistributing it and thereby contributes to the irregular change on the cutting forces in one tooth periods. In this paper, in order to avoid the numerical oscillations from differential model and to eliminate the influence of the ill-posed problem in calibration, a new approach to calibrate the cutter radial run-out parameters from the continuous cutting force model with constant cutting coefficients was proposed. Through analyzing the influence of the ill-posed problem in calibration of the tangential and radial cutting force coefficients, the corresponding solution method was proposed to enhance the calculation stability and to get a useful and stable solution. The cutting force coefficient matrix was optimized by incorporating the average cutting information in x and y directions based on the least square method. Furthermore, through numerical simulation and experimental results, the validity of the calibration approach is demonstrated.