Cutting force evolution and its power spectrum analysis with tool wear progress in ultra-precision raster milling

In this paper, cutting force and its power spectrum analysis at different tool wear levels are explored. A dynamic model is established to simulate the measured cutting force compositions, and a series of cutting experiments have been conducted to investigate the cutting force evolution with the tool wear progress. Research results reveal that in the time domain, the cutting force in UPRM is characterized as a force pulse follows by a damped vibration signals, the vibration can be modeled by a second order impulse response of the measurement system. While in the frequency domain, it is found that the power spectrum density at the natural frequency of dynamometer increases with the progress of tool wear, which therefore can be utilized to monitor diamond tool wear in UPRM.