Modelling and simulation of the high-speed milling process based on MATLAB-SIMULINK

Machining processes constitute some of the most used procedures of metals processing. This paper shows the implementation, in MATLAB-SIMULINK, of a mechanistic model that relates the cutting forces and the torque in the high-speed milling (HSM) process to the generalized geometry of the tool and cutting parameters. The implemented model predicts the magnitudes of the cutting forces and the resulting torque. The main equations of the cutting process and the equations to calculate the radial chip thickness for 3 dimensional free-form machining are presented. In addition, it introduces the kinematics of the entry and exit radial immersion angles. This model is validated with data collected experimentally, demonstrating its effectiveness. Furthermore, the model can be used in systems of supervision and control of HSM using the predicted cutting forces and torque to determine the possible appearance of faults such as tool wear, tool breakage and the presence of vibration or chatter.