New procedures for calibration of instantaneous cutting force coefficients and cutter runout parameters in peripheral milling

In this paper, new procedures are proposed to calibrate the instantaneous cutting force coefficients and the cutter runout parameters for peripheral milling. By combining with optimization algorithm, i.e., the Nelder–Mead simplex method, detailed calibration schemes are derived for a mechanistic cutting force model in which the cutting force coefficients are described as the exponential functions of the instantaneous uncut chip thickness. Three different cutter runout models are considered in the calculation of instantaneous uncut chip thickness. Only one or two tests are required to perform the calibration. Experimental verifications are also conducted to validate the proposed procedures, and the results show that they are efficient and reliable. To see the effect of different runout models on milling process, comparisons among the predicted results under a wide range of cutting parameters are made to study the consistency and limitations of different models. It is found that the radial cutter runout model is a recommendable one for cutting force modelling.