The authors discuss a novel approach to estimation of individual tooth runout in milling. The approach is based upon a simplified linear force model and leads to good results at high values of immersion. Two variants of the approach for estimating runout are presented. The first method utilizes torque while the second considers in plane force components as indicators of runout. Simulations are used to verify the equations that were derived for relating runout to in plane forces and to allow the assessment of the influence of the spacing of the discrete force samples on accuracy. Experimental evidence validates the approach for a wide range of immersion values. Experiments also show that the approach is able to identify edge breakage in the presence of significant initial runout.

Issue Section:
Research Papers
Topics:
Milling, Engineering simulation, Simulation, Torque
1.
Yellowley
I.
, “
A Note on the Significance of the Quasi Mean Resultant Forces and the Modeling of Instantaneous Torque and Forces in Peripheral Milling Operations
,”
ASME Journal of Engineering for Industry
, Vol.
110
,
1988
, pp.
300
–
303
.
2.
Yellowley, I., Hosepyan, Y., and Oyawoye, O., “The Identification of Machining Conditions and Tracking of Tool Wear in Milling using Machining Forces,” Materials Issues in Machining and the Physics of Machining Processes, ASME Winter Annual Meeting, 1992, pp. 11–130.
3.
Wang
J. J.
,
Liang
S. Y.
, and
Book
W. J.
, “
Convolution Analysis of milling Force Pulsation
,”
ASME Journal of Engineering for Industry
, Vol.
116
,
1994
, pp.
17
–
25
.
4.
Liang
S. Y.
, and
Wang
J. J.
, “
Milling Force Convolution Modeling for Identification of Cutter Axis Offset
,”
Int. J. Mach. Tools Manufact.
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34
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8
,
1994
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1177
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1190
.
5.
Gu, F., Kapoor, S.G., DeVor, R.E., and Bandyopadhyay, P., “An Approach to On-Line Cutter Runout Estimation in Face Milling,” Trans. NAMRl/SME, 1991, pp. 240–247.
6.
Yellowley, I. Ardekani, R., Yang, L., and Seethaler, R.J., “The Development of Robust Extensible Control Architectures for Machine Tools,” SPIE, Photonics East Conference, Boston 1996.
7.
Yellowley
I.
, “
Observations on the Mean Values of Forces, Torque and Specific Power in the Peripheral Milling Process
,”
Int. J. Mach. Tools Manufact.
, Vol.
25
, No.
4
,
1985
, pp.
337
–
346
.
8.
Kline
W. A.
, and
DeVor
R. E.
, “
The Effect of Runout on Cutting Geometry and Forces in End Milling
,”
Int. J. Mach. Tools Manufact.
, Vol.
23
, No.
2/3
,
1983
, pp.
123
–
140
.
9.
Wang
K. J.
, and
Liang
S. Y.
, “
Chip Load Kinematics in Milling With Radial Cutter Runout
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
118
,
1996
, pp.
111
–
116
.
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