Dynamic force modelling for a ball-end milling cutter based on the merchant oblique cutting theory

A new dynamic force model for a ball-end milling cutter is presented in thi s paper. Based on the principle of the power remaining constant in cuts, th e Merchant oblique cutting theory has been successfully used for the differ ential cutting edge segment of a ball-end milling cutter. A concise method for characterising the relationship of the complex geometry of a ball-end m illing cutter and the milling process variables is determined so that the f orce coefficients can be decomposed. The geometric property of a ball-end m illing cutter and the dynamics of the milling process are integrated into t he general model to eliminate the need for the experimental calibration of each cutter geometry and milling process variable. The milling experiments prove that this model can predict accurately the cutting forces in three Ca rtesian directions.