In-process prediction of cutting depths in end milling

In geometric adaptive control systems for the end milling process, the surface error is usually predicted from the cutting force owing to the close relationship between them, and the easiness of its measurement. Knowledge of the cutting depth improves the effectiveness of this approach, since different cutting depths result in different surface errors even if the measured cutting forces are the same. This work suggests an algorithm for estimating the cutting depth based on the pattern of cutting force. The cutting force pattern, rather than its magnitude, better reflects the change of the cutting depth, because while the magnitude is influenced by several cutting parameters, the pattern is affected mainly by the cutting depth. The proposed algorithm can be applied to extensive cutting circumstances, such as presence of tool wear, change of work material hardness, etc. (C) 1999 Elsevier Science Ltd. All rights reserved.