A novel multi-harmonic and phase-independent estimation of cutting force coefficients

A novel frequency domain approach is proposed to estimate the cutting force coefficients through a dedicated analytical formulation. The method uses the amplitudes of the Fourier series harmonics and does not require any phase information. When compared to the average cutting force approach, the proposed method gives better accuracy even when few data points are used along the tool path. The method is verified by machining Ti6Al4V alloy with a variable pitch-helix tool using straight and slope cutting; the predicted coefficients are also validated by comparing them with those obtained using commercial machining simulation software.