A general method for calibration of milling force coefficients and cutter runout parameters simultaneously for helical end milling

This paper proposes a new method to simultaneously calibrate the milling force coefficients and the cutter runout parameters in helical end milling. The linear cutting force model is utilized with the consideration of the runout of the cutter, and the mathematical relationships between the instantaneous milling forces and the milling force coefficients are expressed by an underdetermined system of linear equations. Then the least squares method is employed, and a calibration procedure is presented by defining an objective function, which is utilized to estimate the deviations between the simulated results and the measured results. Finally, experimental studies are carried out to verify the accuracy of the milling force coefficients and the cutter runout parameters calibrated by the proposed method. Results indicate that the predicted results agree well with the experiment results, and the errors of predicted results are much smaller than those of the average force method, which means that the proposed method has a higher accuracy than the average force method.