Fast evaluation of cutting forces in milling, applying no approximate models

A new method for fast evaluation of cutting forces in milling is introduced and tested experimentally. Unlike all existing procedures, which include the use of cutting models and approximate assumptions, in this method, the elementary functions of the cutting force are obtained from measured values only. The basic force functions for the whole feed range are acquired from one experiment using a single-tooth full-diameter (slot) milling, applying a specially developed procedure. The milling experiment is conducted under low-impact conditions, enabling accurate measurement and convenient signal processing. The basic force functions are then integrated and superimposed, using known procedures, to combine the total force in any multitooth milling combination. In this work the method is explained and tested experimentally. The suggested method enables a reliable evaluation of the cutting forces, while demanding minimal experimental work, the method applies to cutters having complicated edge geometry, and to high speed milling.