A Solid Modeler Based Engagement Model for 5-axis Ball End Milling

5-axis sculptured surface milling is a difficult machining process to model due to the complex geometrical engagement between the workpiece and the cutter. Due to the complexity of the process, the engagement cannot be found analytically with conventional methods. Therefore, solid modeler based simulations are utilized to compute the engagement map. This paper presents a comprehensive and efficient strategy for engagement modeling of ball end milling using a solid modeler kernel, namely Parasolid. Accuracy of the model is validated by simulating the cutting forces based on the calculated engagements and compare it with experimentally measured cutting forces.