Abstract
In milling with 5-axis machining center, the attitudes of tool or workpiece are controlled by tilting 2 axes, so the milling can be performed by outer portion of cutting edge having large cutting velocity. In order to predict cutting forces in above milling with ball end mills, a cutting model proposed in previous paper has been extended to milling process in which both cutting edges of the spherical and cylindrical portions engage with the workpiece. Cutting forces under various attitudes in pick-feed milling is predicted by using the cutting model. As a result, the appropriate tool tilting angle, which gives small variation of the cutting forces with rotational angle and non-overcut caused by tool deflection for milling with pick-feed, were obtained. In this report, to estimate the machining error in milling for various attitudes, tool deflection is analyzed by using the FEM model of the ball end mill developed in previous paper. In the analysis, predicted results of cutting forces are used. It is shown that the tool deflection varies considerably by the given pick-feed direction.
