Cutting Force Transition Model Considering the Influence of Tool System by Using Standard Test Table

Area of Science:

• Mechanical Engineering
• Manufacturing Processes

Background:

• Classical cutting force prediction models rely on oblique transformation, converting orthogonal cutting parameters to predict forces.
• These models often neglect tool vibration, leading to significant discrepancies between predicted and measured cutting forces.

Purpose of the Study:

• To develop an enhanced cutting force conversion model that incorporates the influence of tool vibration.
• To improve the accuracy of cutting force prediction in milling operations.

Main Methods:

• A novel cutting force conversion model was developed by superimposing additional forces generated by tool vibration onto an orthogonal model.
• The proposed model integrates tool system dynamics, specifically tool vibration, into the prediction framework.

Main Results:

• Experimental milling results demonstrate that the proposed model achieves higher prediction accuracy for cutting forces.
• The enhanced model shows a significant improvement in accuracy compared to the original conversion model that does not account for vibration.

Conclusions:

• Tool vibration has a substantial impact on cutting force prediction accuracy.
• The developed cutting force conversion model, considering tool vibration, offers a more reliable prediction of actual cutting forces in milling.