Model-based identification of tool runout in end milling and estimation of surface roughness from measured cutting forces

This paper presents a model-based approach for the identification of tool runout and the estimation of surface roughness from measured cutting forces. In the first part of the paper, the effect of tool runout on variations in the cutting forces and the effect on surface roughness generation are studied. Thereby, several influencing parameters are identified and examined systematically. Based on theoretical considerations, systematic relationships between tool runout, resultant process force variations, and surface roughness characteristics are deduced. The sensitivity of process force variation is investigated for varying runout parameters by experimental tests. In the next part, the model-based runout identification method is developed, which identifies runout parameters accurately from the measured process forces. The approach has been tested extensively and was verified by measured runout parameters and the correlation of surface roughness characteristics of the machined workpiece. The performance of the developed approach is demonstrated in the final part by comparing the result of the model-based surface reconstruction with the measured surface topography.