Application of mechanistic force models to features of arbitrary geometry at low material removal rate

This paper presents a workpiece discretization method to apply existing cutting force models to predict the forces generated during low material removal rate robotic machining operations of features with arbitrary geometry. Two machining operations along a straight edge which are modelled using this feature discretization method are shown, a chamfer pass on a sharp corner and the removal of a trapezoidal cross section. The workpiece features are measured using a high-resolution laser profile scanner to obtain the volume of the features to be removed. The identified features are discretized into rectangular sections such that the cutting force models can be applied to predict the cutting forces. A linear and an exponential mechanistic model which relate tool immersion and feed rate to the cutting force are applied to the scanned workpiece features. The linear and nonlinear models show good agreement with the measured data, with the exception that the linear model occasionally over predicts the forces depending on the radial depth of cut.

Automated summary

This paper introduces a workpiece discretization method to predict cutting forces during low material removal rate robotic machining, with specific models for operations along straight edges. The method involves measuring workpiece features using a high-resolution laser scanner, discretizing the features into rectangular sections for applying cutting force models. Linear and exponential mechanistic models relating tool immersion and feed rate to cutting force show good agreement with measured data, except for occasional over prediction by the linear model based on radial depth of cut.