A Review of Proposed Models for Cutting Force Prediction in Milling Parts with Low Rigidity

Abstract

Milling parts with low rigidity (thin-walled parts) are increasingly attracting the interest of the academic and industrial environment, due to the applicability of these components in industrial sectors of strategic interest at the international level in the aerospace industry, nuclear industry, defense industry, automotive industry, etc. Their low rigidity and constantly changing strength during machining lead on the one hand to instability of the cutting process and on the other hand to part deformation. Solving both types of problems (dynamic and static) must be preceded by prediction of cutting forces as accurately as possible, as they have a significant meaning for machining condition identification and process performance evaluation. Since there are plenty of papers dealing with this topic in the literature, the current research attempts to summarize the models used for prediction of force in milling of thin-walled parts and to identify which are the trends in addressing this issue from the perspective of intelligent production systems.

Cyber–Physical Systems for High-Performance Machining of Difficult to Cut Materials in I5.0 Era—A Review

“…Model-based controllers were the first developed online process optimization systems to regulate the CNC motions, considering the external limits and variations in cutting conditions [158]. The main difficulties in implementing these systems to deal with complex and harsh cutting conditions are the complex computations required in real time and the dependency of the system on the accuracy and reliability of the external sensors [159,160]. For example, the force measurement sensors are sensitive to shock and rapid fluctuations of the cutting parameters, resulting in a high noise-to-signal ratio of the acquired signals [161].…”