Abstract: The model of ball-end cutter milling forces is studied. The algorithm to identify the engaging cutting edges is proposed using Z-map simulation model in ball-end milling process. The expression of instantaneous chip thickness is discussed by analyzing the effects of cutter eccentricity and deflection. Then ball-end cutter milling forces simulation model is established on the basis of the relationship between milling force and chip load. At the same time, the simulation results agree well with those obtained from experiments and show that the presented milling forces model considering cutter eccentricity and deflection can predict milling forces correctly.

Key words: CAM, milling forces model, Z-map model, ball-end mill cutter, cutter eccentricity, cutter deflection