Development of mechanistic models for the prediction of machining performance: Model building methodology

In this paper, recent research efforts at the University of Illinois at Urbana-Champaign (UIUC) on the development of machining process models are summarized under a unified mechanistic modeling framework. The fundamental elements of the basic cutting force model are described first, which include the computation of chip load and chip flow, force transformation relations, workpiece-cutter intersection algorithm, and the model calibration procedure. Some advanced model enhancements are then presented, such as the modeling of process faults, modeling of chip-control tools, and the incorporation of ploughing and tool wear effects. The integration of the process model with the machining system dynamics is discussed next. Finally, representative results are shown to validate the mechanistic modeling approach.