An in-depth analysis of the synchronization between the measured and predicted cutting forces for developing instantaneous milling force model

This paper proposes an analytical approach to synchronize the measured and predicted cutting forces for calibrating instantaneous cutting force coefficients that vary with the instantaneous uncut chip thickness in general end milling. Essential issues such as the synchronization criterion, phase determination of measured cutting forces, specification of calibration experiments and related cutting parameters are highlighted both theoretically and numerically to ensure the calibration accuracy. A closed-form criterion is established to select cutting parameters ensuring the single tooth engagement. Numerical cutting simulations and experimental test results are compared to validate the proposed approach.