Modeling of Five-Axis Ball-End Milling with Tool Orientation Effects

Abstract

An accurate and fast estimation of cutting forces is necessary for improving the performance of five-axis milling. However, the engagement between cutter and workpiece is very complex and irregular, it represents the main challenge for the prediction of cutting forces. This research aims to present a cutting force model of five-axis ball end milling, in which the effects of lead and tilt angles are investigated. The simulation results show that the resultant cutting force and total engagement area between cutter and workpiece are increased rapidly when the tilt and lead angles are close to zero. The cutting forces under different tool orientations are analyzed. The results of the proposed approach are successfully evaluated by the existing model.