Feedrate optimization for worn cutter with measured cutting force in rough milling

In machining process, machining condition including tool wear is always changing, selection of feedrate according to real-time machining condition is very important for machining efficiency improvement in practical machining process. In this paper, a feedrate optimization method with measured cutting force in rough milling by considering tool wear is developed. Cutting force model for worn cutter is established, shearing force and friction effect force are modelled by considering tool wear. Mean cutting force formula is also derived for worn cutter, it is used in online monitoring to get real-time machining condition as well as for optimized feedrate calculation. Next, mathematical model of feedrate optimization problem is described. Minimum machining time is set as the optimization objective, mean cutting force and tool wear rate are taken as constraints. After that, details for solving of the optimization problem are presented. Relationship between resultant cutting force and feedrate established and a locally nearly linear relationship is obtained. Optimized feedrate is calculated with the relationship and then verified by the tool wear rate constraint. Finally, the developed method was validated by cutting test.