Identification of cutting force coefficients for the linear and nonlinear force models in end milling process using average forces and optimization technique methods

Abstract

In this paper, the linear and nonlinear mathematical force models are presented for an end-milling process. The nonlinear force model is compared with the updated linear force model. The mechanistic identification of the cutting force coefficients for the linear and nonlinear force models of the end milling process is presented with experimental validation. The cutting force coefficients are determined for an end-milling process using two methods, the average force method and the optimization technique method. The average force method uses equations given by Altintas and Budak [1, 2, 3] for calculating the cutting coefficients of the linear force model. However, the equations for the nonlinear model are derived and used in this paper. The second method uses the optimization technique for identifying the cutting coefficients in the milling process by forming objective functions using the optimization technique to minimize the error between the experimental and the analytical forces. Moreover, this method produced a good force model that approximates the experimental force results, which compared with the average force method for both models.