In-process prediction of cutting depths in end milling

In geometric adaptive control systems for the end milling process, the surf ace error is usually predicted from the cutting force owing to the close re lationship between them, and the easiness of its measurement. Knowledge of the cutting depth improves the effectiveness of this approach, since differ ent 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 cutt ing depth, because while the magnitude is influenced by several cutting par ameters, the pattern is affected mainly by the cutting depth. The proposed algorithm can be applied to extensive cutting circumstances, such as presen ce of tool wear, change of work material hardness, etc. (C) 1999 Elsevier S cience Ltd. All rights reserved.