An accuracy algorithm for chip thickness modeling in 5-axis ball-end finish milling

Chip thickness in milling is one of the most fundamental parameters, which can significantly affect cutting force, cutting heat, cutting stability and machined surface topography for computer-aided process planning. In this paper, a combination of a three-dimensional trochoidal tooth trajectory model (3D3T) and engagement-boundary chip model is developed to determine instantaneous chip thickness in 5-axis ball-end finish milling. In comparison with the chip volume measured in a commercial software package (Unigraphics) the accuracy of the proposed model has been numerically validated with various process parameters including cutting depth, tool–workpiece inclination and cutter runout. The differences in time-varying delay and dynamic chip thickness as well as stability are compared with different models to show the impact of using 3D3T mechanism for chip thickness modeling in 5-axis ball-end finish.

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► An accuracy chip thickness model is proposed for ball-end finish milling.
► 3D-trochoidal tooth trajectory (3D3T) and engagement boundary effect are included.
► The model can reduce prediction error by one order compared with classical ones.
► Time-varying delay duo to 3D3T can shift stability lobes in ball-end finish milling.