Ball end milling mechanistic model based on a voxel-based geometric representation and a ray casting technique

Prediction of machining forces involved in complex geometry can be valuable information for machine shops. This paper presents a mechanistic cutting force simulation model for ball end milling processes, using ray casting and voxel representation methods used in 3D computer graphics field. Using this method, instantaneous uncut chip cross sectional areas can be extracted, which can be used in cutting pressure coefficient extraction and machining simulation including machining forces and geometry of the workpiece. The major advantage of the proposed scheme is that it can simulate milling processes with arbitrary cutting tool geometry on a workpiece with complex geometry, using an algorithm with constant time complexity. A series of cutting experiments were carried out to validate the model.