A calculation method on dynamic force feedback in complex free-form contour pre-generation

In this paper, an approximate inverse algorithm is described to calculate the dynamic cutting force applied on the complex free-form contour pre-generation. In traditional contour milling process, cutting force can be generally determined by installing force transducers or sensors. However, conveniently and easily controllable tool is one of important considerations in complex contours generation since its non-gentle slopes and curvatures. The proposed algorithm focuses on the calculation of a dynamic feedback force by dealing with both minimum and non-minimum phase systems. According to the information of the output tool position and input driving force, the dynamic cutting force information can be calculated out by the approximate inverse approach. Therefore, force transducers or sensors are eliminated and the disadvantages are prevented accordingly. Experiments have been carried out under empty-/rough-/fine-generating conditions, showed that depth of feed is one of the important factors affects the dynamic force, and it is feasible to calculate cutting force effectively in complex contour generation without force transducers or sensors installment.