Estimation of the specific cutting pressures for mechanistic cutting force models

This paper presents a new method for the estimation of specific cutting pressures for mechanistic cutting force models for the face milling process. Traditional methods for the estimation of specific cutting pressures require calibration tests using a single cutting insert on a workpiece which has no surface discontinuities. However, face milling operations in the industry are typically performed on workpieces that have workpiece surface discontinuities and using a large number of cutting inserts to enhance productivity. The performance of calibration tests to determine specific cutting pressures is usually very expensive. Hence, a new method to estimate specific cutting pressures directly from cutting force data collected during actual production is developed. The results obtained using the traditional and the new method are validated through simulations and experimental tests. (C) 2000 Elsevier Science Ltd. All rights reserved.