An analytical modeling for process parameter planning in the machining of Ti-6Al-4V for force specifications using an inverse analysis

The reverse computation methodology is proposed to obtain the process parameters for force specifications. A physics-based model along with an iterative gradient search method is employed to design the process parameters such as cutting velocity and depth of cut from the experimentally determined cutting forces. In order to obtain the desired cutting forces, it is required to have a systematic approach to determine the process parameters. An iterative gradient search procedure based on Kalman filter is set up to adaptively approach the specific forces by the optimization of process parameters such that an inverse reasoning can be achieved. A physics-based model is used to predict the cutting forces in each iteration based on shear deformation and chip formation model, as proposed by Oxley. The experimental data are used to illustrate the implementation and validate the viability of the computational methodology.