Effect of ball end mills errors on cutting forces

The size of the removed chip area in 3-axis high speed ball end milling is affected by cutting Parameters, and changes throughout the point of contact between the cutter and the workpiece. This change is primarily caused by bending, runout, and vibrations resulting from the cutting forces. A new method has been created to calculate the equivalent radius of the tool, based on these machining defects, which is then used to determine the new cutting geometry parameters such as the limitations of the cutter workpiece engagement (CWE) region, uncut chip thickness, and cutting width. The CWE region is divided into three zones according to the path's nature and intersections for the elementary cutting edges. To establish a milling force predictive model for three-axis ball end milling, the thermomechanical approach is used, including these machining errors. To validate the model, tests were performed on AISI 4142 steel with a coated carbide ball end tool. The instantaneous values of cutting forces were measured, and the simulated and measured values showed good agreement, with a difference not exceeding around 8, 61% for the X component, 10% for the Y component, and 1% for the Z component in terms of maximal value.