Simulation of cutting forces in ball-end milling

The paper presents a simulation system (SCP) that determines the cutting forces in the ball-end milling process. The system is based on numerical methods, computer programme, theoretical knowledge of technological processes, machining and tests performed. The system for simulation of the cutting process combines the technological data base, the analytical and experimental model and the data base SCP. The experimental model contains a collection of variables of the cutting process by means of sensors and transformation of those data into numerical values, which are a starting point for data calculation of characteristic coefficients of materials. The analytical model is used to estimate the tangential, radial and axial cutting forces, along with a material data base obtained from cutting experiments. Ball-end milling test has been conducted to verify simulation results. The simulation results, are the basis for the development of the tool-designing model and for the model of optimization of the machining process cutting parameters. (C) 2003 Elsevier Science Ltd. All rights reserved.