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An approach for static and dynamic
simulation of ball-end milling of die surfaces is presented in this paper. It has the capability of estimating the static and dynamic cutting forces and tool deflections for various cutting conditions. A conm1ercially available geometric engine (ACIS) is used to represent the cutting edge, cutter and updated part. To detem1ine cutting edge engagement for each tool rotational step, the intersections between the cutting edge and boundary of the contact face between tool and updated part are determined. The engaged portion of the cutting edge is divided into small differential oblique cutting edge segments and the static cutting force components are
calculated by sul1ID1ing up the differential
cutting forces. In dynamic simulation, the dynamic chip thickness is computed by summing up the static chip thickness, the tool deflection and the undulation left from the previous tooth. For calculating the ploughing forces, wu' s model is extended to the ball-end milling process. The total forces, including the cutting and ploughing forces, are applied to the structural vibratory model of the system and the dynamic deflections at the tool tip are predicted. A series of experiments were also perfom1ed to verify the proposed approach.