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Estimating Cutting Force Coefficients in High-Speed Low-Radial-Immersion Milling Processes

[+] Author Affiliations
Josiah A. Bryan, Roger C. Fales

University of Missouri, Columbia, MO

Paper No. DSCC2014-5930, pp. V002T35A002; 10 pages
  • ASME 2014 Dynamic Systems and Control Conference
  • Volume 2: Dynamic Modeling and Diagnostics in Biomedical Systems; Dynamics and Control of Wind Energy Systems; Vehicle Energy Management Optimization; Energy Storage, Optimization; Transportation and Grid Applications; Estimation and Identification Methods, Tracking, Detection, Alternative Propulsion Systems; Ground and Space Vehicle Dynamics; Intelligent Transportation Systems and Control; Energy Harvesting; Modeling and Control for Thermo-Fluid Applications, IC Engines, Manufacturing
  • San Antonio, Texas, USA, October 22–24, 2014
  • Conference Sponsors: Dynamic Systems and Control Division
  • ISBN: 978-0-7918-4619-3
  • Copyright © 2014 by ASME


A high-speed milling system is considered, which is prone to chatter vibration, a stability condition dependent on system parameters (e.g., cutting force coefficients). This work is motivated by the need for model parameters which can be used in stability analysis. An Extended Kalman Filter (EKF) is proposed to estimate cutting force coefficients for each tooth in a low-radial-immersion milling process to aid chatter stability prediction. The proposed EKF utilizes tool deflection measurements and no force measurements. The model used in the EKF is found to be observable, a quality required to achieve valid state estimations. Running the EKF with experimental tool deflection measurements produces estimates of cutting force coefficients that result in good correlation between simulation (using the estimated coefficients) and experiment. Such an EKF may help customize chatter stability analysis to any particular tool-workpiece system.

Copyright © 2014 by ASME
Topics: Cutting , Milling



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