Mechanistic modeling of the ball end milling process for multi-axis machining of free-form surfaces

A mechanistic modeling approach to predicting cutting forces is developed f or multi-axis ball end milling of free-form surfaces. The workpiece surface is represented by discretized point vectors. The modeling approach employs the cutting edge profile in either analytical or measured form. The engage d cut geometry is determined by classification of the elemental cutting poi nt positions with respect to the workpiece surface. The chip load model det ermines the undeformed chip thickness distribution along the cutting edges with consideration of various process faults. Given a 5-axis tool path in a cutter location file, shape driving profiles are generated and piecewise r uled surfaces are used to construct the tool swept envelope. The tool swept envelope is then used to update the work-piece surface geometry employing the Z-map method. A series of 3-axis and 5-axis surface machining tests on Ti6A14V were conducted to validate the model. The model shows good computat ional efficiency and the force predictions are found in good agreement with th measured data.