Date of Award

Winter 2012

Project Type


Program or Major

Mechanical Engineering

Degree Name

Master of Science

First Advisor

Barry Fussell


A Smart Machining System being developed at UNH has the potential to produce high quality machined parts in minimum time. Integral to the success of this system is the ability to accurately simulate cutting forces. In this current work, a time-domain milling simulation is developed with a tool-workpiece compliance model to predict dynamic cutting forces. The simulation computes milling forces, tool deflections, and workpiece vibration (surface waviness).

The accuracy of the simulation depends on finding reliable system parameters. In this work, an end milling parameter identification method is developed using linear predictive coding (LPC) and Extended Kalman Filtering. The milling simulation model is validated by comparison of simulation and experimental forces for a variety of end milling cuts. In-cut and out-of-cut damping is shown to be significantly different, and must be considered in the simulation model. This milling force simulation is shown to predict chatter reasonably well under controlled cuts.