Abstract
This study deals with an analysis of workpiece behavior for milling of a shaft having a small flexural rigidity using ball end mills. In this paper, in order to apply a previously developed cutting model to milling of shafts, geometric quantities such as contact region between the cutting edge and the workpiece surface, and distribution of undeformed chip thickness along the cutting edge are analyzed. Cutting forces are calculated by using the cutting model and an energy method. Then, the workpiece deflection is analyzed based on calculated results of cutting forces, and the variation of the above quantities with tool rotational angle are compared at various tool locations on the workpiece. It is found that the cutting forces and workpiece deflection became large at the location where the tool axis reaches about half of the center line of the shaft.
