Cutter workpiece engagement region and surface topography prediction in five-axis ball-end milling

Abstract

ABSTRACTBased on the machining tool path and the true trajectory equation of the cutting edge relative to the workpiece, the engagement region between the cutter and workpiece is analyzed and a new model is developed for the numerical simulation of the machined surface topography in a multiaxis ball-end milling process. The influence of machining parameters such as the feed per tooth, the radial depth of cut, the angle orientation tool, the cutter runout, and the tool deflection upon the topography are taken into account in the model. Based on the cutter workpiece engagement, the cutting force model is established. The tool deflections are extracted and used in the surface topography model for simulation. The predicted force profiles were compared to the measured ones. A reasonable agreement between the experimental and the predicted results was found.