A generic framework for modeling milling forces in structured anisotropic materials: Application to unidirectional and woven glass fiber-reinforced polymers

This paper presents a generic and systematic methodology for identifying coefficients of a mechanistic cutting force model for structured anisotropic materials, focusing on unidirectional and woven fiber-reinforced polymers (FRPs). The model predicts three-directional cutting forces using cutting and edge coefficients described by a second-order Fourier series. An identification procedure includes spindle speed correction, signal alignment, and revolution averaging. Coefficients are estimated from milling experiments at three feed-per-tooth values via gradient-based optimization. Validated on Glass FRPs, the model demonstrates accuracy within and beyond calibration conditions, enabling cutting forces prediction across structured anisotropic materials with minimal experimental effort and no structural information.