Multi-axis ball-end milling force prediction model considering the influence of cutting edge.

Precise prediction of milling force is a crucial issue in multi-axis milling, which is important for evaluating the tool life and surface quality. In this paper, an improved force model for ball-end milling is proposed based on a novel uncut chip thickness (UCT) model as well as the consideration of edge effect and size effect. The computational model of UCT takes into account the influence of lead and tilt angles in ball-end milling. In addition, it utilizes a new discretization method of the uncut chip area that ensures the local cutting edge is perpendicular to the length of the elemental uncut chip area, making it more compatible with the classical oblique cutting model. For each elemental cutting edge, the force components are calculated through a purely analytical approach, considering the shear force, edge force, and size effect caused by cutting edge geometry in milling process. The proposed model is comprehensively validated with both FEM and multi-axis milling experiments for aluminum and titanium. The results indicate that the proposed model can predict the dynamic milling force under various cutting conditions in a good manner. Moreover, considering edge and size effects can further improve the prediction accuracy. [ABSTRACT FROM AUTHOR]