Cutting force model for high speed machining process

Abstract

This paper presents cutting force-based models able to describe a high speed machining process. The model considers the cutting force as output variable, essential for the physical processes that are taking place in high speed machining. Moreover, this paper shows the mathematical development to derive the integral-differential equations, and the algorithms implemented in MATLAB to predict the cutting force in real time. MATLAB is a software tool for doing numerical computations with matrices and vectors. It can also display information graphically and includes many toolboxes for several research and applications areas. Two end mill shapes are considered (i.e., cylindrical and ball end mill) for real-time implementation of the developed algorithms. The developed models are validated in slot milling operations. The results corroborate the importance of the cutting force variable for predicting tool wear in high speed machining operations. The developed models are the starting point for future work related with vibration analysis, process stability and dimensional surface finish in high speed machining processes.