Precise Estimation of Cutting Force Coefficients and Cutter Runout in Milling using Differential Evolution Algorithm

Abstract

An optimization method for calibrating cutting force coefficients and cutter runout parameters is developed in this study. The optimization technique works by minimizing the difference between the measured force and predicted force for all force components. Formulation of the instantaneous uncut chip thickness demonstrates that the total measured cutting forces can be separated into a nominal component independent of cutter runout and a perturbation component induced by cutter runout. Based on the differential evolution algorithm, the cutting force coefficients are identified via the nominal components of cutting forces, then the cutter runout parameters are determined from the perturbation components of cutting forces. The experimental results indicate that, compared with the linear-edge force model, the cutting forces predicted by the proposed method agree better with the measured forces both in magnitude and in waveform distribution.