Improved dynamic cutting force model in ball end milling - Part 1: Theoretical modelling and experimental callibration

X. Liu, K. Cheng, A.P. Longstaff, M.H. Widiyarto, D. Ford

    Research output: Contribution to journalArticlepeer-review

    18 Citations (Scopus)


    An accurate cutting force model of ball-end milling
    is essential for precision prediction and compensation of tool
    deflection that dominantly determines the dimensional accuracy
    of the machined surface. This paper presents an improved theoretical
    dynamic cutting force model for ball-end milling. The
    three-dimensional instantaneous cutting forces acting on a single
    flute of a helical ball-end mill are integrated from the differential
    cutting force components on sliced elements of the flute
    along the cutter-axis direction. The size effect of undeformed
    chip thickness and the influence of the effective rake angle are
    considered in the formulation of the differential cutting forces
    based on the theory of oblique cutting. A set of half immersion
    slot milling tests is performed with a one-tooth solid carbide
    helical ball-end mill for the calibration of the cutting force coefficients.
    The recorded dynamic cutting forces are averaged to fit
    the theoretical model and yield the cutting force coefficients. The
    measured and simulated dynamic cutting forces are compared
    using the experimental calibrated cutting force coefficients, and
    there is a reasonable agreement. A further experimental verification
    of the dynamic cutting force model will be presented in
    a follow-up paper.
    Original languageEnglish
    Pages (from-to)457-465
    JournalInternational Journal of Advanced Manufacturing Technology
    Publication statusPublished - 2005


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