The Influence of Tool Orientation on Cutting Forces during End Milling

This article presents the results of single-factor modeling and analysis of the influence of tool orientation with regard to the tilt angle and lead angle, on cutting forces when finish milling by a ball end cutter. The program NX 10 is used to build boundaries and contact areas of the tool and the workpiece, and the SIMULIA ABAQUS software is used to create a three-dimensional finite element model and determine the cutting forces. Graphs that describe dependencies of the cutting forces on the tool rotation angle are obtained for different orientations of the tool axis relative to the surface normal. The computational results will allow transition to the two-factor analysis of the influence of tilt angle combinations on the cutting forces and the determination of the optimal tool orientation during five-axis milling with maximum productivity.

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