Modelling of cutting forces in ball-end milling with tool–surface inclination: Part II. Influence of cutting conditions, run-out, ploughing and inclination angle

This study focuses on the influence of tool–workpiece inclination on cutting forces in ball-end milling. Cutting forces calculated from a thermomechanical modelling, presented in part I of this paper [M. Fontaine, A. Moufki, A. Devillez, D. Dudzinski, Modelling of cutting forces in ball-end milling with tool–surface inclination. Part I. Predictive force model and experimental validation, J. Mater. Process. Technol. 189 (2007) 73–84], are here discussed in detail and compared to experimental results. The proposed modelling of ball-end milling was applied to machining operations with straight tool paths and various tool–surface inclinations. Both ramping and contouring configurations were studied. The experimental results were obtained from ball-end milling tests performed on a three-axis CNC equipped with a Kistler dynamometer. The attention is here pointed on the shape and level of the cutting forces signals. The evolution of the maximum values of cutting forces acting on the tool is investigated in order to identify the optimum inclination angle. Influences of cutting conditions, radial run-out and ploughing on cutting forces and cutting stability are discussed.