Physical modeling and simulation for the milling process of the ball end mill

With the geometry model of the ball end mill, the method of theoretic cutting force analysis combined with the identification of the experimental coefficients of milling forces is used to develop the milling force model of a helical ball end mill. The vibration model of ball end milling process concerning the effect of cutter flexibility is presented. Based on the feedback of dynamic milling deflection of the cutter and the wave on the milled surface on the cutting thickness, the dynamic model of ball end milling is developed, and the dynamic milling process is simulated at the same time. It is shown that offline simulation can give accurate predictions to the dynamic features of milling process.