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A general method for calibration of milling force coefficients and cutter runout parameters simultaneously for helical end milling

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Abstract

This paper proposes a new method to simultaneously calibrate the milling force coefficients and the cutter runout parameters in helical end milling. The linear cutting force model is utilized with the consideration of the runout of the cutter, and the mathematical relationships between the instantaneous milling forces and the milling force coefficients are expressed by an underdetermined system of linear equations. Then the least squares method is employed, and a calibration procedure is presented by defining an objective function, which is utilized to estimate the deviations between the simulated results and the measured results. Finally, experimental studies are carried out to verify the accuracy of the milling force coefficients and the cutter runout parameters calibrated by the proposed method. Results indicate that the predicted results agree well with the experiment results, and the errors of predicted results are much smaller than those of the average force method, which means that the proposed method has a higher accuracy than the average force method.

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All data generated or analyzed during this study are included in this published article.

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Funding

This research is supported by the National Natural Science Foundation of China (No. 52005413), Natural Science Basic Research Program of Shaanxi (No. 2020JQ-183), Shaanxi Key Research and Development Projects (No. 2019KW-018), and National Science and Technology Major Project of China (No. 2018ZX04005001).

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Authors and Affiliations

  1. Engineering Research Center of Advanced Manufacturing Technology for Aero Engine (Northwestern Polytechnical University), Ministry of Education, Xi’an, 710072, China

    Zhao Zhang, Zepeng Liang, Ming Luo, Baohai Wu & Dinghua Zhang

  2. Key Laboratory of High Performance Manufacturing for Aero Engine (Northwestern Polytechnical University), Ministry of Industry and Information Technology, Xi’an, 710072, China

    Zhao Zhang, Zepeng Liang, Ming Luo, Baohai Wu & Dinghua Zhang

Authors
  1. Zhao Zhang
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  2. Zepeng Liang
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  3. Ming Luo
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  4. Baohai Wu
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  5. Dinghua Zhang
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Contributions

Zhao Zhang designed the framework of the paper and provided data analysis; Zepeng Liang wrote the paper and carried out the experiments; Ming Luo provided the experimental condition; Baohai Wu helped with the experiments; Dinghua Zhang contributed to the main idea of the paper.

Corresponding author

Correspondence to Ming Luo.

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Zhang, Z., Liang, Z., Luo, M. et al. A general method for calibration of milling force coefficients and cutter runout parameters simultaneously for helical end milling. Int J Adv Manuf Technol 116, 2989–2997 (2021). https://doi.org/10.1007/s00170-021-07657-4

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  • DOI: https://doi.org/10.1007/s00170-021-07657-4

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