Prediction of flank wear and engagements from force measurements in end milling operations

Abstract On-line knowledge of tool engagement and flank wear is critical for successful adaptive control of a machining operation. A method combining a mechanistic model and empirical relationships has been developed for helical end milling operations. Computation of cutting tool engagements and flank wear width occurs in real time as the cutting progresses using averaged force data. Response surface methodology has been used to investigate the effects of the process and operating variables on the process-dependent parameters; a second order relationship was obtained. The approach can also determine variation of wear land width along the length of the tool as axial engagement changes.

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