Modeling and simulation of micro-ball-end milling forces

Taking the micro-ball-end milling forces as research object, the cutting edge model was analyzed. The tool was discreted into several cutting units along the axis, and the actual instantaneous uncut chip thickness of each cutting unit was calculated according to single edge cutting and two edges cutting respectively. The cutting edge segments were extracted by solid modeling, and the instantaneous cutting force coefficients as well as tool runout parameters were identified by experiments. A micro-ball-end milling forces model was developed, in which tool runout, scale effect and possible single edge cutting phenomenon in micro-milling were synthetically considered. Experimental results demonstrated the validity and feasibility of the micro-ball-end milling forces model.