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This article presents a method of a cutting force prediction in the case of a ball-end milling. We have proposed a geometrical description of a generic tool so as to simulate the 3 axis milling operation with a hemispherical ball-end cutter. This tool is decomposed into elementary discs; a mechanical approach of the cut is applied onto each disc to obtain the cutting forces from the machined material behaviour and from the cutting conditions. The model, thus obtained, will be afterward generalised in the case of an inclined or circular surface. This generalisation is carried out by adopting, at each time, an adequate reference change, dependent on the trajectory inclination angle. For application, we will consider the milling of a complex part. In fact, the synthesized cut model will be applied to the different types of surfaces which constitute this workpiece; and this will be executed according to the two machining senses: longitudinal and transversal. (Received in January 2008, accepted in May 2008. This paper was with the authors 1 month for 1 revision.)

Simulation of cutting forces for complex surfaces in ball-end milling