Discrete Cutting Force Model for 5-Axis Milling with Arbitrary Engagement and Feed Direction

5-axis machining operations bring new challenges for predicting cutting forces. Complex tool workpiece engagements and tool orientations make it difficult to adapt 3-axis process models for 5-axis operations. A new model is developed to predict cutting forces with arbitrary tool/workpiece engagement and tool feed direction. A discretization approach is used, in which the tool is composed of multiple cutting elements. Each element is processed to determine its effect on cutting forces, and global forces are determined by combining the elemental effects. Cutting tests are conducted to verify force predictions, where the tool/workpiece engagement is provided through a geometric software application.