Cutting force prediction for five-axis ball-end milling considering cutter vibrations and run-out

Cutting force during 5-axis end-milling is affected by many factors in a complex manner. The accuracy of a cutting force prediction algorithm is determined by how these factors are integrated into the cutting force model. In this paper, a cutting force prediction algorithm considering the influence of cutter vibrations and cutter run-out is proposed. Both factors affect cutting force through influence on the uncut chip thickness. The effect of cutter run-out is modelled as an extra feed for machining, which produces a cyclic change on the uncut chip thickness. Meanwhile, for cutter vibrations, by solving the differential motion equation with the measured modal parameters, real-time vibrations of the cutter during machining are obtained, which are taken as a feedback of the machining system on the designed feed-per-tooth. As shown with experiments, the predictions made with the proposed algorithm produce better conformity with actual machining forces.