Mean cutting force prediction in ball-end milling using force map method

In this paper, a new method is proposed to predict mean cutting force in ball-end milling of sculptured surfaces. The cutter contact area, which is obtained from Z-map of the hemispherical part of the cutter, is expressed as a set of grids on the cutter plane orthogonal to the cutter axis. Before calculation of cutting force, cutting force density in each grid is calculated using empirical cutting parameters. The calculated force density corresponding to the grid position on the cutter plane is defined as a force map. The mean cutting force in an arbitrary cutter contact area is easily calculated by summing up the cutting force densities of the engaged grids in the force map. The proposed method was verified through the slotting and slanted surface machining by varying the surface inclination angle. From the experimental results, it was shown that mean cutting force can be calculated accurately and fast.