A new procedure for the prediction of the cutting forces in peripheral milling

This paper presents a new method for calibrating the cutting force coefficients and the cutter runout parameters simultaneously in peripheral milling. In order to reflect the size effect, the lumped-mechanism model is employed, in which the instantaneous cutting force coefficients are treated by an exponent function of the instantaneous uncut chip thickness. To calibrate the empirical force coefficients, the mathematical relationships between the instantaneous cutting forces and the instantaneous uncut chip thickness are established with the initial runout parameters firstly. Then, the cutting force coefficients can be obtained by solving the contradiction equations with least-squares fitting method. Thereafter, the normalized mean square error is achieved by comparing the simulation results and the experiment results. The particle swarm optimization method is adopted to predict the cutting force coefficients and the runout parameters by minimizing the normalized mean square error. Finally, the milling tests over a wide range of cutting conditions are conducted to verify the proposed method, and the results show that the predicted cutting forces agree well with the experiment results. Besides, the method proposed in this paper has higher prediction accuracy than the average force method.