IJAT Vol.10 No.2 pp. 253-261
doi: 10.20965/ijat.2016.p0253

Technical Paper:

Development of Cutting Force Prediction Method Using Motion Information from CNC Controller

Tomoya Hida*,†, Tetsuya Asano*, Chiharu Higashino*, Masaaki Kanamaru*, Jun’ichi Kaneko**, and Yoshimi Takeuchi***

*Aikoku Alpha Corporation
Morikami, Sobue, Inazawa, Aichi 495-8501, Japan

Corresponding author,

**Graduate School of Science and Engineering, Saitama University
255 Shimo-Okubo, Sakura-ku, Saitama City, Saitama 338-8570, Japan

***Department of Mechanical Engineering, Chubu University
1200 Matsumoto, Kasugai, Aichi 487-8501, Japan

September 29, 2015
November 30, 2015
Online released:
March 4, 2016
March 5, 2016
cutting force, prediction, CNC, NC data, motion error
Five-axis machines and multi-tasking machines are widely used because they facilitate integration of work processes and simplification of jigs and set-ups. Along with effective machine use, development of optimum machining such as research on tools and cutting methods to achieve high-speed cutting and increase of material removal rate is being investigated. While these efforts have greatly contributed to furthering of automation and cost reduction at the manufacturing site, complex machine motions and increased demanding work processes can lead to unexpected collisions and tool breakages. To prevent tool breakage caused by unexpected overloading or to improve the inefficient feed rate on the basis of safety considerations, simulations based on numerical control (NC) data are usually performed in advance to evaluate the cutting force. In high-speed, high-efficiency machining, however, the machine does not always execute movements as instructed by the NC data and the predicted cutting force does not always agree with the actual cutting forces. In this study, therefore, we developed an off-line system in which the motion information of each axis of an actual machine is acquired from a computer numerical control (CNC) controller, and is then used to predict the cutting force. The effects of using the proposed method are described in this article.
Cite this article as:
T. Hida, T. Asano, C. Higashino, M. Kanamaru, J. Kaneko, and Y. Takeuchi, “Development of Cutting Force Prediction Method Using Motion Information from CNC Controller,” Int. J. Automation Technol., Vol.10 No.2, pp. 253-261, 2016.
Data files:
  1. [1] Y. Takeuchi and T. Watanabe, “Generation of 5-axis Control Collision-Free Tool Path and Postprocessing for NC-Data,” Annals of the CIRP, Vol.41, No.1, pp. 539-542, 1992.
  2. [2] B. Lauwers, J. P. Kruth, P. Dejonghe, and R. Vreys, “Efficient NC-Programming of Multi-Axes Milling Machines Through the Integration of Tool Path Generation and NC-Simulation,” Annals of CIRP, Vol.49, No.1, pp. 367-370, 2000.
  3. [3] X. Tian, H. Deng, M. Fujishima, and K. Yamazaki, “Quick 3D Modelling of Machining Environment by Means of On-machine Stereo Vision with Digital Decomposition,” Annals of CIRP, Vol.56, No.1, pp. 411-414, 2007.
  4. [4] M. Kanamaru, N. Sakai, A. Goto, and T. Hida, “Development of Simulation Technology for 5-Axis Machines – Verification of Material Removal Model and Collision Avoidance –,” Int. J. of Automation Technology, Vol.1, No.2, pp. 141-146, 2007.
  5. [5] T. Hida, T. Asano, K. Nishita, N. Sakai, A. Goto, and Y. Takeuchi, “Development of Online Real-Time Collision Free Machining Using Simulation with CNC Openness,” Int. J. of Automation Technology, Vol.9, No.4, pp. 403-410, 2015.
  6. [6] S. Takata, M. D. Tsai, M. Inui, and T. Sata, “A Cutting Simulation System for Machinability Evaluation Using a Workpiece Model,” Annals of the CIRP, Vol.38/1/1989, pp. 417-420, 1989.
  7. [7] H. Narita, K. Shirase, H. Wakamatsu, and E. Arai, “Pre-process Evaluation of Machining Accuracy Using Virtual Machining Simulator,” JSME Int. J. Series C, Vol.43, No.2, pp. 492-497, 2000.
  8. [8] VERICUT Website: html [accessed Oct., 2014]
  9. [9] NCBRAIN Website: index.html [accessed Oct., 2014]
  10. [10] L. Almad, J. Kaneko, K. Horio, and T. Yamazaki, “Development of Tool Motion Estimation Method for Cutting Force Prediction in High Speed Machining,” MJIIT-JUC Joint International Symposium, 2015.
  11. [11] R. Sato, M. Tsutsumi, and K. Nagashima, “Dynamic Behavior of Feed Drive Systems around Quadrant Changes in Circular Motion,” Journal of the Japan Society for Precision Engineering, Vol.72, No.2, pp. 208-213, 2006.
  12. [12] AdvantEdge Website: [accessed Feb., 2015]
  13. [13] T. Matsumura, I. Hori, T. Shirakashi, and E. Usui, “Simulation of Drilling Process Based on Energy Approach,” Proceedings of the 8th International ESAFORM Conference on Material Forming, Vol.2, pp. 757-760, 2005.
  14. [14] T. Matsumura, T. Shimada, and K. Teramoto, “Analysis of Cutting Process on Machining Centers,” Proceedings of the International Conference on Leading Edge Manufacturing in 21st Century, pp. 1093-1098, 2005.
  15. [15] T. Shimada, K. Teramoto, and T. Matsumura, “Development of Cutting Simulation System for Machining of Mold and Dies,” Proceedings of the International Conference on Leading Edge Manufacturing in 21st Century, pp. 1099-1104, 2005.
  16. [16] T. Matsumura, T. Shirakashi, and E. Usui, “Prediction of Milling Process Based on 2D FEM Simulation,” Proceedings of the 9th International ESAFORM Conference on Material Forming, Vol.2, pp. 623-626, 2006.
  17. [17] Y. Altintas and A. Spence, “End Milling Force Algorithms for CAD Systems,” Annals of the CIRP, Vol.40/1/1991, pp. 31-34, 1991.
  18. [18] J. Kaneko and K. Horio, “Fast Cutter Workpiece Engagement Estimation Method for Prediction of Instantaneous Cutting Force in Continuous Multi-Axis Controlled Machining,” Int. J. of Automation Technology, Vol.7, No.4, pp. 391-400, 2013.

*This site is desgined based on HTML5 and CSS3 for modern browsers, e.g. Chrome, Firefox, Safari, Edge, Opera.

Last updated on Jun. 19, 2024