Abstract
An approach is presented to simulate cutting processes with tilted ball end mills. An energy approach, which makes the chip flow model with pilling up orthogonal cuttings in the plane containing the cutting velocities and the chip flow velocities, is extended to apply to the operations on multi-axis machine tools: The tilted tool in the plane perpendicular to the feed direction is interpreted as machining of the inclined workpiece at a tilt angle. The tilted tool in the direction of the cutter feed is analyzed with coordinate transformation from the general coordinate system to the coordinate system inclined at a tilt angle. Based on the orthogonal cutting data, the chip flow model can be made to predict the cutting force with the chip flow direction. The comparison of the analysis results with the measured cutting forces verifies the presented model based on the energy approach.
