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A virtual machining simulator (VMSim) for the flat end mill has already been developed, hence the VMSim for a ball end mill is developed in this research. This system consists of a geometric simulator and a physical simulator to evaluate the machining process. A direct calculation method of machining error copy points is newly proposed to represent the machining errors due to tool deflection in the geometric simulation, and the cutting force and the machining error prediction models for the ball end mill are also introduced in the physical simulation in this research. Furthermore, a basic modification of tool paths in order to reduce the machining errors is introduced. In case studies, the modification of tool paths is carried out and the feasibility of trial-less machining is discussed.

Trial-Less Machining Using Virtual Machining Simulator for Ball End Mill Operation