Accurate and fast measurement of specific cutting force coefficients changing with spindle speed

Prediction of cutting forces is essential to simulate dynamic effects of the milling process, and optimize process parameters to reduce detrimental vibrations. Cutting forces are conventionally modeled by assuming a dependence on uncut chip thickness using dedicated coefficients, to be experimentally identified. These coefficients are proven to vary significantly with spindle speed, causing the need of a time-consuming experimental phase to achieve an accurate simulation of cutting forces in a wide range of spindle speeds. This paper presents a method to efficiently identify the specific cutting force coefficients in the entire speed range by a single milling test, in which spindle speed is ramped-up. During the test, the forces signals are acquired and then processed to identify the speed-varying cutting force coefficients. The method was applied to the identification of Aluminum 6082-T4 coefficients in a wide range of speeds and results were validated through traditional approach, proving the efficiency and effectiveness of the proposed technique. In addition, an application of the obtained coefficients to chatter prediction is presented and validated through chatter tests.