Compilation of program-loading spectrum for milling of a motorized spindle based on cutting force model

A new compiling method based on cutting force model is proposed for an eight-block program-loading spectrum of a motorized spindle. In the proposed method, all loads exerted on the motorized spindle are dependent, which is accurate for loading in reliability tests. A cutting force measuring system is set up to obtain cutting forces accurately. Then, two concluded cutting force models are compared to choose the better one through fitting the measured cutting force signals under different machining process parameters. In accordance with the characteristic of the milling load, program-loading spectrum for the amplitude of radial force is compiled while neglecting other factors. Thereafter, the compiled spectrum is converted into a complete program-loading spectrum where torque and loads’ correlation are calculated by the chosen cutting force model. Finally, the accelerated factor of the program-loading spectrum relative to actual machining conditions is solved.