Determination of cutting-condition-independent coefficients and runout parameters in ball-end milling

Abstract

This paper presents a systematic and practical method for determining cutting-condition-independent coefficients in ball-end milling. An approach for estimating the runout offset and its location angle is also described based on a single cutting force measurement. An in-depth analysis of the characteristics of these cutting coefficients, which can be determined from only a few test cuts, is provided. The size effect is also modelled, including the characteristics of the ball-end mill geometry, and incorporated into the cutting force model. This method of estimating the 3D ball-end milling force coefficients was tested experimentally for various cutting conditions and gave excellent cutting force predictions. Also, the estimated values of the runout offset agreed well with the measurements.