Abstract:

This paper represents a comprehensive strategy for estimation of tool deflection in five-axis ball-end milling operation. The cutter-work piece contact zone is computed using a solid modeler kernel and based on that, instantaneous cutting forces are estimated using a mechanistic model. Finite Element Method (FEM) method is employed to simulate the deflection of tool during the cutting process. The proposed model is evaluated by conducting some experiments. Effectiveness of the proposed strategy is considering cutting force as a distributed load along cutting edge, simplicity and less computation time.