Tool cutting force modeling in ball-end milling using multilevel perceptron

Abstract This paper uses the artificial neural networks (ANNs) approach to evolve an efficient model for estimation of cutting forces, based on a set of input cutting conditions. A neural network algorithms are developed for use as a direct modeling method, to predict forces for ball-end milling operation. Supervised neural networks are used to successfully estimate the cutting forces developed during end milling process. The training of the networks is preformed with experimental machining data. The predictive capability of using analytical and neural network approaches are compared using statistics, which showed that neural network predictions for three cutting force components were for 4% closer to the experimental measurements, compared to 11% using analytical method. Exhaustive experimentation is conduced to develop the model and to validate it. The milling experiments prove that this model can predict accurately the cutting forces in three Cartesian directions. The force model can be used for simulation purposes and for defining threshold values in cutting tool condition monitoring system.