Comparison of Tangential Force Models for Feedrate Selection in Milling

Several mechanistic force models are investigated for use in a feedrate selection system that uses average spindle cutting power for model calibration. Strategies for feedrate selection using a spindle power sensor are discussed. Five different flat end mill force models are considered, some with an edge effect component and some with a size effect component. The models are evaluated for average tangential force prediction accuracy and ease of calibration using a variety of experiments with different flat end mills and workpiece materials. A method of showing all the experimental data points and tangential force model predictions on one plot is developed. The models are shown to be much more accurate than a simple volumetric power model in predicting average tangential force. The performances of all the mechanistic force models are similar, with the linear edge effect model and the nonlinear size effect model showing the most potential for feedrate selection.