Machining, Measurement, and Control Laboratory

On the Monitoring of Cutting Forces in End Milling Processes (2nd Report)
-- An Application to the Identification of a Prediction Model of Cutting Forces within Canned Cycles and Feedrate Control ---

Soichi Ibaraki, Atsushi Matsubara, Tomohiro Yasuda, Yoshiaki Kakino, Masanori Murozumi

Control strategies of cutting forces in end milling process have been long studied as a methodology to autonomously optimize cutting conditions. In particular, a model-based feedforward control approach has been recognized as a simple, and yet practical way to regulate the cutting force. This paper proposes an identification scheme of a prediction model of cutting force, and a feedrate control scheme based on it. Model identification cycles are included within a canned milling cycle, where the cutting force is estimated from servo motor current and spindle motor current in order to identify the cutting force prediction model. By performing cutting force control in subsequent processes based on the identified model, it is experimentally validated that the machining efficiency is significantly improved, while avoiding an excessive tool load.