Abstract
This paper focuses on the mathematical modeling for 5-axis milling with a filleted end mill. Several coordinate systems are introduced to describe the relationship between a cutter orientation and a machined surface. Then, a cutting point on a cutting edge is geometrically formulated as an integrated form of some expressions. The fundamental simulations based on the modeling were implemented to investigate the characteristics of path-interval and feed-interval scallops on a machined surface; moreover, path interval determination is proposed for suitable estimation in filleted end milling. As a result, it was found that the proposed approach could provide the characteristics of microscopic topography in detail.
