Five-axis milling mechanics for complex free form surfaces

Accurate and fast prediction of machining forces is important in high performance cutting of free form surfaces that are commonly used in aerospace, automotive, biomedical and die/mold industries. This paper presents a novel and generalized approach for prediction of cutting forces in five-axis machining of parts with complex free form surfaces. Engagement simulations between cutter and part are performed precisely along the tool path by a recently developed boundary representation method. Moreover, mathematical model for five-axis milling mechanics is developed for any given solid model of parts with complex free form surfaces. Theoretical simulations and experimental validations show that cutting forces are predicted fast and precisely for five-axis machining of complex free form surfaces.