Abstract
An approach is presented to simulate cutting process in the machining with curved-edge end mill, which has cutter radius and rake angle changing with cutter height. Those geometrical parameters are defined as functions of cutter height in the presented approach. Chip flow in the milling process is modeled as a pilling up of orthogonal cutting planes containing cutting velocity and chip flow velocity. Shear plane model can be made by orthogonal cutting data, which associates shear angle, shear stress and friction angle with rake angle. Chip flow direction can be given to minimize cutting energy calculated in the cutting model made. Cutting force can be predicted with cutting model having the minimum cutting energy. Some examples are shown to verify the presented approach in the machining with ball end mill and roughing end mill.
