Abstract:
Milling is widely used in the fields of aerospace and automotive manufacturing. Predicting milling forces is an important way to improve the quality and efficiency of part processing, and high-precision calibration of milling force coefficients is the key to predicting milling forces. The milling process is influenced by various factors. Traditional milling force coefficient calibration methods are based on the theoretical relationship between tool and workpiece, but ignore the influence of other factors on the milling force coefficient in actual machining. Based on the milling force model, the semi analytical calculation model of face milling force coefficient is derived. The tangential force, radial force and feed force are obtained through milling experiments. Considering the impact of peak cutting force on tool and workpiece vibration, a correction factor is introduced to correct the local cutting force coefficient. Finally, based on the calibrated coefficients, the milling force was predicted and experimentally validated. The maximum relative error between the theoretical prediction and experimental values of the milling force was 11.4%, and the predicted and experimental values were close with relatively small relative errors. Therefore, the method proposed in this article can effectively calibrate the surface milling force coefficient.