Abstract
A new cutting force model considering the influence of cutter deflection is introduced in this research for sculptured surface machining with ball-end mill. After the cutting force model of Lee and Altintas is introduced, undeformed chip thickness considering feed rate, eccentricity of cutting edge and cutter deflection is modelled. By obtaining the cutter-workpiece contact areas based on geometries of the cutter and the sculptured surface, the mathematical model for estimating the total cutting forces in different directions is then developed. Experiments have also been conducted to measure the cutting forces. The analytically estimated cutting forces considering the cutter deflection match better with the actual cutting forces obtained through experiments than the model without considering the cutter deflection.
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