Machining error prediction by considering increase of cutting force due to tool wear

Calculation of real cutting length and modeling of increase of cutting force

Abstract

Cutting force increases due to tool wear which causes additional machining error. In this paper, a machining error prediction model by considering the effect of tool wear is presented. Real cutting length at each cutting edge position is calculated, and the increase of cutting force and the recession of the cutting edge are modeled as a function of the real cutting length. The presented model was verified with cutting experiments of radius end milling of S55C. The machining errors showed a good agreement with the prediction and were decreased from 49μm to 7μm by applying the prediction on the tool paths modification.