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<article data-uid="">
<h1 id="measurement">Measurement</h1>
<p>How a physical quantity gets from a real cutter or a real cut into the model. These are protocols
rather than theory: follow them and the simulation is fed a measured number instead of a default.</p>
<p>Ordered from the cutter on the bench, through the instrument that watches it, to the cutter in the
cut and the experiment that has to be designed before it.</p>
<ul>
<li><a href="radial-angle-measurement.html">Radial Angle Measurement</a> — Reading the radial rake and radial relief angles off a cutting-plane scan</li>
<li><a href="smart-tool-holder.html">Smart Tool Holder</a> — The moment arm and installation angle that decide whether the holder's torque is scaled right at all</li>
<li><a href="smart-holder-training.html">Smart Holder Training</a> — The three cut shapes and the conditions that let a smart tool holder train milling coefficients</li>
<li><a href="training-cut-set-design.html">Designing a Training Cut Set</a> — The two degeneracies that leave a coefficient unrecoverable whatever the data quality, and the helix and feed spread that remove them</li>
</ul>
<h2 id="see-also">See Also</h2>
<ul>
<li><a href="../milling-physics/index.html">Milling Physics</a> — the model these measurements feed</li>
</ul>
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<article data-uid="Technique-RadialAngleMeasurement">
<h1 id="radial-rake-angle-and-radial-relief-angle-measurement-on-the-cutting-plane">Radial Rake Angle and Radial Relief Angle Measurement on the Cutting Plane</h1>
<p>The method for measuring angles on the tool cutting plane scan is illustrated below:</p>
<p><img src="radial-angle-measurement-img/clip-cutter-angle-scheme.jpg" alt="Tool angle measurement"></p>
<h2 id="radial-rake-angle-α">Radial Rake Angle (α)</h2>
<ol>
<li>Sweep along the tool rotation direction to find the trailing point A of the cutting edge</li>
<li>Connect point A to the center O</li>
<li>The angle ∠OAA' between line OA and the first polyline endpoint A' on the cutting side of the edge is the rake angle α</li>
</ol>
<h2 id="radial-relief-angle-β">Radial Relief Angle (β)</h2>
<ol>
<li>Find the contact point B between the tool and the envelope circle</li>
<li>Construct the tangent line Lt to the envelope circle at point B</li>
<li>BB' is the first line segment on the relief side of the tool</li>
<li>Pick an arbitrary point B'' on Lt in the relief direction</li>
<li>The angle ∠B'BB'' between BB' and Lt is the relief angle β</li>
</ol>
<h2 id="see-also">See Also</h2>
<ul>
<li><a class="xref" href="../milling-physics/relief-face-avoidance.html">Relief Face Avoidance</a> — the minimum relief angle the measured β has to clear</li>
<li><a class="xref" href="../milling-physics/cutter-geometry.html">Cutter Geometry</a> — the cutter description these angles are part of</li>
</ul>
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%
G40 G17 G49 G54 G80
G91 G28 Z0.0
T01 M06
S1500 M03
G43 Z10. H01
G01 G90 X2. Y-20. M08
G01 Z-1. F600.
G01 Y16.
Z10.
G01 X14. Y-20.
G01 Z-1. F600.
G01 Y16.
Z10.
G01 X26. Y-20.
G01 Z-1. F600.
G01 Y16.
Z10.
G00 G90 X-20. Y10.
G17 G01 Z-1. F600.
S50 M03
;@MachiningResolution_mm=0.0625;
;@SetNcResolutionFeedPerTooth();
X13. F20. ;@LineSelection("lineA",AnchorMode.FirstTouch,AnchorMode.LastTouch);
X25. F10. ;@LineSelection("lineB",AnchorMode.FirstTouch,AnchorMode.LastTouch);
S1500 M03
Z10. F600.
G91 G28 Z0.
T02 M06
S50 M03
G43 Z10. H02
G01 G90 X10. Y30. M08
G01 Z-4. F20. ;@LineSelection("drillA",AnchorMode.FirstTouch,AnchorMode.LastTouch);
Z10.
X20.
G01 Z-4. F10. ;@LineSelection("drillB",AnchorMode.FirstTouch,AnchorMode.LastTouch);
Z10.
M09
M05
G91 G28 Z0.0
M30
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<article data-uid="Technique-SmartHolderTraining">
<h1 id="smart-tool-holder-coefficient-training">Smart Tool Holder Coefficient Training</h1>
<p>By cutting the following shapes and collecting three-direction torques with a smart tool holder, you can train milling coefficients through HiNC projects.</p>
<h2 id="overview">Overview</h2>
<p><img src="smart-holder-training-img/training-path-diagram.png" alt="Smart Tool Holder Coefficient Training Path Diagram"></p>
<ul>
<li>T1 End mill D10 4 flutes</li>
<li>T2 Drill bit, diameter unrestricted</li>
</ul>
<p>Click to download <a href="smart-holder-training-img/train.nc">NC code</a>.</p>
<div class="NOTE">
<h5>Note</h5>
<p><strong>Adjusting Machining Method</strong></p>
<ul>
<li>Speed and feed can be changed according to material conditions, but feed per tooth must be in multiples.</li>
<li>Slower spindle speed allows the smart tool holder to collect more data per unit time.</li>
<li>The wall thickness between the two slots in <a href="#shape-i">Shape I</a> needs to be thin enough so that <a href="#shape-ii">Shape II</a> cutting is discontinuous per revolution.</li>
</ul>
</div>
<h2 id="shape-i">Shape I</h2>
<p>Shape I consists of three red slots, which are preparatory shapes, no need to collect smart tool holder data.</p>
<ul>
<li>ae10; ap1; S1500; F600</li>
</ul>
<h2 id="shape-ii">Shape II</h2>
<p>Shape II penetrates through the thin walls between the three red slots, need to collect smart tool holder data.</p>
<ul>
<li>lineA: T1; ap1; S50; F20 (frt0.1)</li>
<li>lineB: T1; ap1; S50; F10 (frt0.05)</li>
</ul>
<h2 id="shape-iii">Shape III</h2>
<p>Shape III is drilling, need to collect smart tool holder data.</p>
<ul>
<li>drillA: T2; dp4; S50; F20</li>
<li>drillB: T2; dp4; S50; F10</li>
</ul>
<h2 id="see-also">See Also</h2>
<ul>
<li><a href="training-cut-set-design.html">Designing a Training Cut Set</a> — what a set of passes has to span before the coefficients are recoverable at all</li>
<li><a href="smart-tool-holder.html">Smart Tool Holder</a> — the moment arm and installation angle a training run assumes are already right</li>
<li><a class="xref" href="../machine-capability/cam-floating-point-drift.html">CAM Floating-Point Drift</a> — a measurement error source to rule out before trusting a training run</li>
<li><a class="xref" href="../milling-physics/milling-physics-coordinates.html">Milling Physics Coordinates</a> — the spindle-rotation frame the holder's torques are reported in</li>
</ul>
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<article data-uid="Technique-SmartToolHolder">
<h1 id="smart-tool-holder">Smart Tool Holder</h1>
<p>A smart tool holder is a machine tool accessory equipped with sensors that can monitor force and torque data in real time during machining. To ensure simulation accuracy, the following parameters must be configured correctly:</p>
<h2 id="sensor-configuration">Sensor Configuration</h2>
<h3 id="moment-arm-height">Moment Arm Height</h3>
<ul>
<li>The sensor height setting has a significant impact on simulation accuracy</li>
<li>This height defines the moment arm distance for the torque measured by the sensor</li>
<li>If not set correctly, a constant scaling error will appear in the torque calculation</li>
</ul>
<h3 id="coordinate-system-alignment">Coordinate System Alignment</h3>
<ol>
<li><p><strong>Basic Principle</strong></p>
<ul>
<li>The cutting edge should be aligned with the sensor's X-axis</li>
<li>Ensure the sensor XY coordinate system is consistent with the simulation XY coordinate system</li>
<li>The impact of coordinate system misalignment is relatively smaller compared to the moment arm setting</li>
</ul>
</li>
<li><p><strong>Installation Angle Adjustment</strong></p>
<ul>
<li>If perfect alignment is not possible, measure the offset angle</li>
<li>Enter the measured angle in the &ldquo;Installation Angle&rdquo; field</li>
<li>The maximum possible deviation is 45 degrees</li>
</ul>
</li>
</ol>
<h2 id="factors-affecting-accuracy">Factors Affecting Accuracy</h2>
<h3 id="coordinate-transformation-effects">Coordinate Transformation Effects</h3>
<ul>
<li>An installation angle deviation can cause up to a √2 factor difference in values</li>
<li>This difference is inherently a result of coordinate transformation, not a measurement accuracy issue</li>
<li>Even with the same smart tool holder, different installation angles will produce different measurement data</li>
</ul>
<h3 id="best-practices">Best Practices</h3>
<ol>
<li>Prioritize accurate moment arm height configuration</li>
<li>Align the cutting edge with the sensor X-axis as closely as possible</li>
<li>If perfect alignment is not achievable, always measure and set the correct installation angle</li>
</ol>
<p>Only with these parameters correctly configured will the simulated micro-waveforms match the actual sensor measurements.</p>
<h2 id="see-also">See Also</h2>
<ul>
<li><a href="smart-holder-training.html">Smart Holder Training</a> — the cut shapes and conditions that turn a correctly configured holder into trained milling coefficients</li>
<li><a class="xref" href="../milling-physics/milling-physics-coordinates.html">Milling Physics Coordinates</a> — the frame the holder's forces and torques are reported in</li>
<li><a href="../../manual/setup/cutter.html">Cutter</a> — where the holder's settings are entered in the application</li>
</ul>
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<article data-uid="Technique-TrainingCutSetDesign">
<h1 id="designing-a-training-cut-set">Designing a Training Cut Set</h1>
<p>Training recovers the six milling coefficients by fitting simulated force against measured force
over a set of passes. Whether a given set of cutters and passes can determine those coefficients at
all is a property of the design rather than of the data quality: two specific degeneracies leave a
coefficient unrecoverable however clean the samples are. Each has its own fix, and neither fix
substitutes for the other.</p>
<h2 id="the-two-degeneracies">The Two Degeneracies</h2>
<table>
<thead>
<tr>
<th>What goes wrong</th>
<th>How it shows up in the result</th>
<th>What removes it</th>
</tr>
</thead>
<tbody>
<tr>
<td><strong>The bending-moment plane null.</strong> In rotation-averaged Mx/My one particular combination of the edge and normal shear coefficients is exactly unobservable</td>
<td>Shear coefficients come back orders of magnitude too large, and their signs flip between runs on the same data</td>
<td><strong>Helix diversity</strong> — at least two clearly different helix angles among the cutters trained together</td>
</tr>
<tr>
<td><strong>Slope–intercept collinearity</strong> between the shear and ploughing coefficients, which enter the fit as the slope and the intercept of the same line</td>
<td>The correlation still looks good. Shear comes back low by roughly a tenth, ploughing high by around a half</td>
<td><strong>A spread of feed per tooth</strong> across the passes — a range of chip loads, not a range of depths</td>
</tr>
</tbody>
</table>
<p>A set that fixes one and not the other still fails, and it fails in the manner of the one left
unfixed. Both are properties of the cut set as a whole, so both are decided before any metal is cut.</p>
<h2 id="why-the-helix-angle-is-the-lever">Why the Helix Angle Is the Lever</h2>
<p>The unobservable direction is a combination of the edge and normal shear coefficients weighted by
the cosine and sine of the helix angle. Changing the helix angle does not remove that direction —
it <strong>rotates</strong> it. Two helix angles far enough apart therefore give two different null directions
whose only common point is zero, so the pooled fit has no null at all, and the edge coefficient
becomes identifiable from the measurement alone: no torque channel, no prior value, no externally
supplied phase.</p>
<p>A single helix angle of zero is the worst case, and misleadingly so, because it aligns the null
exactly with the edge-coefficient axis. A cut set built that way returns an edge coefficient that
is null-space fill rather than a value the data demands, while the normal coefficient beside it
comes out as the most accurate number on the page.</p>
<div class="IMPORTANT">
<h5>Important</h5>
<p>At a single helix angle the individual edge and normal shear values are not meaningful on their
own, even when the correlation coefficient is high. A training run is judged by the force it
reproduces over time — see <a class="xref" href="../validation/cutting-force.html">Cutting Force and Torque</a> —
not by the magnitude of any one coefficient.</p>
</div>
<h2 id="flute-count-is-not-a-lever">Flute Count Is Not a Lever</h2>
<p>Adding more passes with the same symmetric multi-flute cutter buys nothing, at any feed. That
sample subspace is degenerate, and more of it stays degenerate: a set made only of symmetric
four-flute passes cannot derive its own cutter phase, and the fit collapses rather than degrading.
What buys identifiability is spread — in helix angle, and in feed per tooth.</p>
<p>Symmetric off-the-shelf cutters are nonetheless sufficient. Custom single-flute grinding is not
required for either fix; a pair of stock two-flute cutters ground at different helix angles carries
the same identifiability, and is what a shop can actually obtain.</p>
<h2 id="engagement-side-cuts-rather-than-slots">Engagement: Side Cuts Rather Than Slots</h2>
<p>The useful excitation comes from passes whose radial engagement is small enough that at most one
helix flute is in contact at a time — the engagement arc narrower than the angular pitch between
flutes. A full slot holds several flutes in the cut at once and averages away the very variation
the fit needs. Stepping a shallow side cut along the edge of the stock produces a set where no pass
is ever a slot.</p>
<p>Adding depth of cut is not a substitute. Depth moves the load without changing the chip load, so it
does nothing for the slope–intercept collinearity that the feed-per-tooth spread exists to break.</p>
<h2 id="see-also">See Also</h2>
<ul>
<li><a href="smart-holder-training.html">Smart Holder Training</a> — the shipped cut shapes these constraints apply to</li>
<li><a class="xref" href="../milling-physics/cutter-geometry.html">Cutter Geometry</a> — where the helix angle this design turns on is described and entered</li>
</ul>
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