Cutting forces and machining error in ball end milling of inclined flat surfaces

This paper describes a theoretical model for the prediction of cutting forc es and machining error in ball end milling of inclined flat surfaces. The i nstantaneous cutting forces are evaluated based on the uncut chip geometry and the properties of tool and workpiece material. The theory of oblique cu tting is employed in this analysis, since the cutting edge of the ball end mill Is helical. The machining errors at various parts of the machined surf ace are evaluated based on tool deflections. This analysis is carried out f or various tool-feed directions along the inclined surface The effects of v arious cutting conditions on cutting forces and machining error are investi gated and discussed. In order to verify the theoretical results, experiment s are carried out in ball end milling of 0.5% carbon steel. The experimenta l and theoretical results compare fairly well.