The precise measurement of process forces is a key tool in research in machining research and for the calibration of corresponding simulation models. It is also becoming increasingly important in industrial applications, for example for process monitoring in the context of Industry 4.0 and for enriching digital shadows with production data. However, the accuracy of such measurements is limited by the frequency-dependent transfer behaviour of the force measurement systems used and their resonance frequency, especially in the case of highly dynamic forces such as those that occur during interrupted cutting during milling. 

The project aims to develop methods that allow an extension of the bandwidth or usable frequency range of these systems. Existing filtering techniques must be calibrated individually for each measurement chain; if the transfer behaviour changes due to material removal and thus a reduction in workpiece mass, repeated recalibrations are required because measurement accuracy deteriorates progressively. Therefore, alongside a deeper understanding of how material removal affects the frequency-dependent transfer behaviour of workpiece-mounted force measurement systems, another goal is to develop modelling techniques that enable evaluation and correction of this influence when applied to milling processes with varying excitation spectra. 

To address this issue, empirical investigations are first carried out to determine the dynamic behaviour of a force measurement system under varying workpiece masses. In addition, a geometric‑kinematic simulation will be developed to efficiently predict the time‑dependent workpiece mass and make it available as an input variable for modelling purposes. Based on the collected data, the so‑called Forcillator Model will be established, a heuristic mathematical model inspired by uncoupled harmonic oscillators that provides a compact description of frequency responses using characteristic peaks. This model allows efficient parameterization using only a few characteristic variables and thus forms the basis for a subsequent interpolation method between different system states with varying mass. By interpolating between Forcillator models, a valid transfer function shall be available for every point in time throughout the milling process. Finally, an evaluation will be conducted regarding the transferability of these methods to other types of force measuring platforms as well as their suitability for industrial applications such as process monitoring or simulation‑based tool wear detection.

The project can make an important contribution to understanding how material removal influences workpiece‑mounted force measurements and thereby enabling significantly more accurate acquisition of highly dynamic process forces - both in scientific research and in industrial applications.