Cutting Forces Calculation and Experimental Measurement for 5-axis Ball End Milling

Calculation technique for cutting forces prediction in 5-axis ball end milling is worked out and realized as computational program. The curvilinear cutting edge is divided into small segments, and the path for each segment is defined. The local cutting forces are than calculated from local chip thickness using mechanistic approach. Total cutting force is a sum of local forces, acting on each of the elements. The influence of tool orientation in 5-axis milling on the cutting force amplitude and impulse shape is investigated. Series of cutting tests with cutting force measurement for various tool orientations are carried out to validate the calculations. The results are applicable for optimization of 5-axis finishing of flexible workpieces such as turbine blades.