Instantaneous Cutting Force Prediction in Ball-end Finishing Milling of Free Form Surfaces

The extraction of chip geometry is a bridge between the Geometry simulation and Physical simulation, as well as a key technology of forecasting the cutting force. In this paper, a new method of chip geometry extraction was proposed in free form surfaces finishing milling with ball end tools. The variable orientation of cutter axis and property of workpiece surface is considered. Firstly, a reasonable and simple cutting model is built. And then on the basis of this model, the calculating methods of uncut chip thickness, actual entry angle and exit angle, length of engaged cutter edge were illuminated in detail. Finally, those chip geometry was introduced into an existing cutting force model presented in comprehensive reviews. Good agreement between the predicted and measured cutting forces has shown that the proposed method provides very accurate results.