Milling Force Modeling of Worn Tool and Tool Flank Wear Recognition in End Milling


The wear state of a cutting tool is an important issue that affects machining quality. Therefore, monitoring tool wear is extremely essential to ensure workpiece quality and improve tool life. This paper models the milling forces of a worn tool and proposes a recognition methodology of milling tool wear state based mostly on the influence relationships between the milling force options and power wear. Within the milling force model, the friction effect force and also the shearing force are treated separately, and also the friction stress distribution on tool flank is described. Then the force model is calibrated and verified through experiments. Within the tool wear recognition methodology, the relationship between the milling force feature vector and power wear is investigated. On this basis, the tool flank wear recognition technique is proposed. A tool wear experiment is performed using superalloy material. Within the experiment, the recognition results are expressed in confidence intervals that will represent the recognized tool wear additional effectively and accurately. Finally, the theme of tool flank wear online monitoring is proposed.

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