Cutting force prediction in ball end milling of sculptured surface with Z-level contouring tool path

From computer-aided to intelligent machining: Recent advances in computer numerical control machining research

“…Kang and Wang [43] also addressed the same cutter-thin wall elastic deformation problem, but only worked out the deformation prediction without offering the compensation solution. Wei et al [44] introduced cutting force calculation using Z-map approximation. Liang and Yao [45] targeted chip formation calculation for ball-end cutters.…”

An integrated prediction model including the cutting process for virtual product development of machine tools

“…A Z-map method is used to calculate the cutter contact area and the engagement angle between the cutter edge and the boundary of cutter contact area. This method allows simulating the cutting forces of transient cuts in contour milling process [24,25]. The instantaneous total cutting forces acting on the end mill can be obtained by adding the cutting forces of all flutes as…”

Mechanistic modeling of five-axis machining with a general end mill considering cutter runout

“…There have been numerous studies on two-dimensional (2D) milling force modeling for flat-end mills [1][2][3], ball-end mills [4][5][6] and general end mills [7][8][9]. Nevertheless, in the field of five-axis milling, most researches focused on the computer-aided manufacturing (CAM) aspect such as tool path planning and collision detection, while few involved the physics of the milling process such as cutting forces.…”

“…Spence et al [16] identified CWE boundaries using a CSG based process simulation system to predict cutting forces. Larue and 6 Altintas [17] extracted the cutter immersion angles for flank milling by intersecting the cutting tool with the workpiece in ACIS solid modeling environment. Recently, Lazoglu et al [18] proposed a novel B-Rep based method to determine the complex CWEs in five-axis milling of free-form surfaces.…”