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<article data-uid="Workflow-ForceTraining">
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<h1 id="workflow-milling-force-parameter-training">Workflow: Milling Force Parameter Training</h1>
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<p>This workflow covers the end-to-end process of training milling force coefficients from sensor data, including data mapping, coefficient training, quality evaluation, and application of the trained parameters.</p>
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<p>Milling coefficients are essential parameters for calculating milling forces. Training derives these coefficients from experimental sensor data (dynamometer or smart tool holder) mapped to simulated toolpaths.</p>
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<pre><code class="lang-mermaid">flowchart TD
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Prereq["Prerequisites<br>(sensor data, project setup)"]
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Resolution["Configure resolution & enable physics"]
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Mapping["Configure data mapping"]
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Simulate["Run simulation with NC file"]
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Export["Export simulation data<br>(WriteShotFiles, WriteStepFiles)"]
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Map["Map sensor data to simulation"]
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Train["Train milling parameters"]
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Evaluate["Evaluate training quality"]
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Apply["Load trained parameters"]
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Prereq --> Resolution --> Mapping --> Simulate --> Export
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Simulate --> Map --> Train --> Evaluate --> Apply
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</code></pre>
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<h2 id="1-prerequisites">1. Prerequisites</h2>
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<p>Before training you need:</p>
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<table>
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<thead>
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<tr>
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<th>Item</th>
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<th>Description</th>
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</tr>
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</thead>
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<tbody>
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<tr>
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<td><strong>HiNC project</strong></td>
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<td>Machine tool, workpiece, fixture, tool house configured</td>
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</tr>
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<tr>
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<td><strong>NC file</strong></td>
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<td>The NC program used during the physical cutting experiment</td>
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</tr>
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<tr>
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<td><strong>Sensor data CSV</strong></td>
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<td>Time-stamped force/torque data from a dynamometer or smart tool holder</td>
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</tr>
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<tr>
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<td><strong>Controller data CSV</strong> (optional)</td>
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<td>Machine controller log with <code>FileNo</code>, <code>LineNo</code>, <code>ActualTime</code> for two-layer mapping</td>
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</tr>
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</tbody>
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</table>
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<h3 id="sensor-data-file-format">Sensor Data File Format</h3>
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<p>The CSV must contain a header row with <code>ActualTime</code> and at least one force/torque channel:</p>
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<table>
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<thead>
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<tr>
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<th>Source</th>
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<th>Headers</th>
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</tr>
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</thead>
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<tbody>
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<tr>
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<td>Dynamometer</td>
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<td><code>Fx</code> (or <code>Workpiece.Fx</code>), <code>Fy</code>, <code>Fz</code></td>
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</tr>
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<tr>
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<td>Smart tool holder</td>
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<td><code>Mx</code> (or <code>Holder.Mx</code>), <code>My</code>, <code>Mz</code></td>
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</tr>
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<tr>
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<td>Accelerometer (optional)</td>
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<td><code>Ax</code>, <code>Ay</code>, <code>Az</code></td>
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</tr>
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</tbody>
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</table>
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<pre><code class="lang-csv">ActualTime,CH1,CH2,Mx,My,Mz
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18:23:54.703,-0.00398,-0.00034,-0.02923,0.10733,0.00409
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18:23:54.704,-0.00194,0.00285,0.04155,-0.04457,0.00448
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...
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</code></pre>
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<div class="TIP">
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<h5>Tip</h5>
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<p>Keep the completed training project archived. When the HiNC training algorithm is updated, you can re-run training from the same project.</p>
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</div>
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<hr>
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<h2 id="2-configure-resolution-and-enable-physics">2. Configure Resolution and Enable Physics</h2>
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<h3 id="resolution">Resolution</h3>
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<p>Use a finer resolution than normal operation for training accuracy:</p>
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<pre><code class="lang-csharp">MachiningResolution_mm = 0.0625; // half or less of production resolution
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MachiningMotionResolution = FeedPerTooth;
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</code></pre>
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<div class="TIP">
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<h5>Tip</h5>
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<p>Training resolution should be ≤ 0.5× the production resolution for better accuracy.</p>
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</div>
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<h3 id="enable-physics">Enable Physics</h3>
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<p><a class="xref" href="../api/Hi.MachiningProcs.SessionShell.html#Hi_MachiningProcs_SessionShell_EnablePhysics">EnablePhysics</a> must be enabled for force calculation:</p>
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<pre><code class="lang-csharp">EnablePhysics = true;
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</code></pre>
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<h3 id="milling-force-cycle-division">Milling Force Cycle Division</h3>
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<p>Set the number of angular divisions per revolution before training. Higher values yield more accurate phase alignment:</p>
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<pre><code class="lang-csharp">MillingForceCycleDivisionNum = 360;
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</code></pre>
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<div class="NOTE">
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<h5>Note</h5>
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<p>This must be set <strong>before</strong> executing <code>TrainMillingPara</code>. A larger value produces a more accurate <code>AngleOffset</code> result and better milling coefficients.</p>
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</div>
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<hr>
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<h2 id="3-configure-data-mapping">3. Configure Data Mapping</h2>
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<p>Depending on your data, choose one of the mapping strategies below.</p>
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<h3 id="31-local-mapping-anchor-based">3.1 Local Mapping (Anchor-Based)</h3>
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<p>For mapping sensor data to specific NC path segments:</p>
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<p><strong>Step A — Specify input data:</strong></p>
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<pre><code class="lang-csharp">ClearTimeMappingData();
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AddTimeDataByFile("lineA", "Mapping/sensor1.csv", "18:25:51.7100", "18:26:12.9910");
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AddTimeDataByFile("lineB", "Mapping/sensor1.csv", "18:26:30.5750", "18:27:12.2880");
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</code></pre>
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<p><strong>Step B — Specify NC paths</strong> (embedded in NC code comments):</p>
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<pre><code>X13. F20 ;@LineSelection("lineA", FirstTouch, ShiftTime_s(2), LineEnd, ShiftDistance_mm(-1));
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X25. F10 ;@LineSelection("lineB", FirstTouch, null, LastTouch, null);
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</code></pre>
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<p>Anchor options: <code>LineBegin</code>, <code>LineEnd</code>, <code>FirstTouch</code>, <code>LastTouch</code>.
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Offset options: <code>null</code>, <code>ShiftTime_s(<seconds>)</code>, <code>ShiftDistance_mm(<mm>)</code>.</p>
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<h3 id="32-two-layer-chained-mapping-controller--sensor">3.2 Two-Layer Chained Mapping (Controller + Sensor)</h3>
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<p>When you have both controller data and sensor data:</p>
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<pre><code class="lang-csharp">PlayNcFile("NC/machining.nc");
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MapSingleByCsvFile("Data/controller.csv"); // maps FileNo/LineNo → ActualTime
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MapSeriesByCsvFile("Data/sensor.csv"); // maps ActualTime → sensor series
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</code></pre>
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<div class="NOTE">
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<h5>Note</h5>
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<p><strong>Why two-layer mapping?</strong> Running the NC through the system interpreter produces more accurate simulation paths than direct CSV playback. The controller data bridges simulation steps to real time via <code>FileNo</code>/<code>LineNo</code>, and the sensor data bridges real time to force/torque readings.</p>
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</div>
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<hr>
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<h2 id="4-run-simulation">4. Run Simulation</h2>
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<pre><code class="lang-csharp">PlayNcFile("NC/file1.nc");
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</code></pre>
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<div class="WARNING">
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<h5>Warning</h5>
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<p>During training, <strong>do not</strong>:</p>
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<ul>
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<li>Adjust workpiece, tool, or controller resolution settings</li>
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<li>Use the NC player reset button (close the project instead)</li>
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<li>Save the project (system training configuration may overwrite tool resolution settings)</li>
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</ul>
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</div>
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<hr>
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<h2 id="5-export-simulation-data">5. Export Simulation Data</h2>
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<p>Export step data and waveform data for analysis:</p>
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<pre><code class="lang-csharp">WriteStepFiles("Output/[NcName].step.csv");
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WriteShotFiles("Output/[NcName].shot.csv", 1);
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</code></pre>
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<p>The shot file contains time-resolved force columns: <code>Tool.Fx/Fy/Fz</code>, <code>Workpiece.Fx/Fy/Fz</code>, <code>Spindle.Mx/My/Mz</code>.</p>
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<p>For coordinate system explanations, see <a href="../manual/analysis/milling-physics-coordinates.html">Milling Physics Coordinates</a>.</p>
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<hr>
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<h2 id="6-train-milling-parameters">6. Train Milling Parameters</h2>
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<h3 id="trainmillingpara-new-training">TrainMillingPara (New Training)</h3>
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<p><a class="xref" href="../api/Hi.MachiningProcs.SessionShell.html#Hi_MachiningProcs_SessionShell_TrainMillingPara_">TrainMillingPara</a> trains new coefficients independently of any existing workpiece parameters.</p>
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<pre><code class="lang-csharp">TrainMillingPara(Fx|Fy|Fz, "StainlessSteel.mp");
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</code></pre>
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<h3 id="retrainmillingpara-calibration">ReTrainMillingPara (Calibration)</h3>
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<p><a class="xref" href="../api/Hi.MachiningProcs.SessionShell.html#Hi_MachiningProcs_SessionShell_ReTrainMillingPara_">ReTrainMillingPara</a> calibrates existing coefficients (10% original weight, 90% new sample weight).</p>
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<pre><code class="lang-csharp">ReTrainMillingPara(Fz|Mx|My|Mz, "StainlessSteel.mp");
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</code></pre>
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<h3 id="sample-flag-requirements">Sample Flag Requirements</h3>
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<table>
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<thead>
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<tr>
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<th>Command</th>
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<th>Minimum Data Types</th>
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<th>Feed Per Tooth Requirement</th>
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</tr>
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</thead>
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<tbody>
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<tr>
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<td><code>TrainMillingPara</code></td>
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<td><code>Fx\|Fy\|Fz</code> (dynamometer) or <code>Fz\|Mx\|My\|Mz</code> (smart tool holder)</td>
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<td>At least one sample with different feed per tooth</td>
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</tr>
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<tr>
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<td><code>ReTrainMillingPara</code></td>
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<td>No restriction</td>
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<td>No restriction</td>
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</tr>
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</tbody>
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</table>
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<div class="WARNING">
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<h5>Warning</h5>
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<p>Using only <code>Mx|My|Mz</code> without <code>Fz</code> loses one degree of freedom (torque = r × F loses the r-direction), making coefficient training unreliable. Always include <code>Fz</code> when using torque data.</p>
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</div>
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<h3 id="training-conditions">Training Conditions</h3>
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<ul>
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<li>Samples should have <strong>stable, repeatable waveforms</strong> for at least two spindle revolutions</li>
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<li>Under unstable conditions, plowing coefficients tend to be over-estimated</li>
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<li>Any NC path shape (slot milling, side milling, any tool shape) is acceptable when samples are stable</li>
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</ul>
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<hr>
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<h2 id="7-evaluate-training-quality">7. Evaluate Training Quality</h2>
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<p>After training, the system reports three quality metrics:</p>
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<h3 id="correlation-coefficient-r">Correlation Coefficient (R)</h3>
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<p>A single value for the overall result. Ranges from 0 to 1; for new tools, expect 0.95–0.999.</p>
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<h3 id="training-error-ratio-trainingerrratio">Training Error Ratio (TrainingErrRatio)</h3>
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<p>A per-step variable registered automatically after training. Lower values indicate better step-level quality:</p>
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<div class="math">
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\[
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\text{TrainingErrRatio} = \sqrt{\frac{\sum_{i} e_i^2}{\sqrt{\sum_{i} y_i^2 \cdot \sum_{i} \hat{y}_i^2}}}
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\]</div>
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<h3 id="angle-offset-angleoffset">Angle Offset (AngleOffset)</h3>
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<p>A per-step variable representing the cutter rotation phase difference between measured and simulated data:</p>
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<div class="math">
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\[
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\theta_{offset} = \frac{2\pi \cdot i_{min}}{N_{div}}
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\]</div>
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<div class="TIP">
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<h5>Tip</h5>
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<p>If <code>AngleOffset</code> varies significantly across segments in the same training batch, the spindle may have experienced speed changes, data gaps, or the system could not accurately analyze the samples.</p>
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</div>
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<hr>
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<h2 id="8-load-trained-parameters">8. Load Trained Parameters</h2>
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<p>After training, load the new coefficients into the workpiece:</p>
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<pre><code class="lang-csharp">LoadCuttingParaByFile("StainlessSteel.mp");
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</code></pre>
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<div class="WARNING">
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<h5>Warning</h5>
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<p>If the training output file path is the same as the tool's existing cutting parameter file, <strong>reload the project</strong> after training to ensure the new parameters take effect.</p>
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</div>
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<hr>
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<h2 id="xml-configuration-gui-workflow">XML Configuration (GUI Workflow)</h2>
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<p>When using the GUI-based training workflow, configure the <code>.hincproj</code> file:</p>
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<pre><code class="lang-xml"><MillingParaGridTrainingDestinationFile>MillingPara/trainedPara.mp</MillingParaGridTrainingDestinationFile>
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<MillingParaTraining>
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<IsMzEnabled>false</IsMzEnabled>
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<ForceOutlierRatio>2</ForceOutlierRatio>
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<LeadParaTemplate>
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<RakeFaceCuttingParaMap>
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<FluteFormNum>1</FluteFormNum>
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<NAngleDivisionNum>0</NAngleDivisionNum>
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<EcAngleDivisionNum>0</EcAngleDivisionNum>
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</RakeFaceCuttingParaMap>
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</LeadParaTemplate>
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<ResultParaTemplate>
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<RakeFaceCuttingParaMap>
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<FluteFormNum>1</FluteFormNum>
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<NAngleDivisionNum>0</NAngleDivisionNum>
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<EcAngleDivisionNum>0</EcAngleDivisionNum>
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</RakeFaceCuttingParaMap>
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</ResultParaTemplate>
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</MillingParaTraining>
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</code></pre>
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<p>Set <code>IsMzEnabled</code> to <code>true</code> if mapped data contains axial spindle torque from a smart tool holder.</p>
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<hr>
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<h2 id="complete-script-example">Complete Script Example</h2>
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<pre><code class="lang-csharp">MachiningResolution_mm = 0.0625;
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EnablePhysics = true;
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MillingForceCycleDivisionNum = 360;
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ClearTimeMappingData();
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AddTimeDataByFile("lineA", "Mapping/sensor1.csv", "18:25:51.7100", "18:26:12.9910");
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AddTimeDataByFile("lineB", "Mapping/sensor1.csv", "18:26:30.5750", "18:27:12.2880");
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PlayNcFile("NC/file1.nc");
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TrainMillingPara(Fx|Fy|Fz, "MillingPara/trained.mp");
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LoadCuttingParaByFile("MillingPara/trained.mp");
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WriteStepFiles("Output/[NcName].step.csv");
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WriteShotFiles("Output/[NcName].shot.csv", 1);
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</code></pre>
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<h2 id="see-also">See Also</h2>
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<ul>
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<li><a href="../manual/analysis/milling-physics-coordinates.html">Milling Physics Coordinates</a> — coordinate system reference</li>
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<li><a href="sensor-mapping.html">Sensor Mapping Workflow</a> — detailed mapping workflow</li>
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<li><a class="xref" href="basic-simulation.html">Workflow: Basic Machining Simulation</a> — basic simulation setup</li>
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<li><a class="xref" href="nc-optimization.html">Workflow: NC Optimization</a> — optimization after training</li>
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<li><a class="xref" href="../manual/runtime/step.html">Step</a> — step data reference</li>
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<li><a class="xref" href="../manual/runtime/session-shell.html">Glossary: SessionShell Quick-Reference</a> — SessionShell quick-reference</li>
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<li><a href="examples/milling-training-dynamometer.html">Training with a Dynamometer (Example)</a></li>
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<li><a href="examples/mapping-demo.html">Cascading Mapping (Example)</a></li>
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</ul>
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</article>
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