Analytical modeling of force system in ball-end milling

This paper establishes an analytical expression for dynamic cutting forces involved in machining with multiflute ball-end cutters. The expression is given in explicit terms of cutting parameters, tool-workpiece geometry, and machining configuration. A model of this nature can assist in the planning of machining operations, the design of machine tool components, the optimization of cutting parameters, and the monitoring/control of process parameters. The concept involved in this model is the mathematical characterization of the cutter-workpiece interaction in terms of the chip width density function in an angular convolution form. This characterization allows the dynamic cutting forces to be algebraically represented in the frequency domain. The analytical development of the model is discussed and the experimental verification presented.