Cutting Force Modeling and Experimental Study for Ball-End Milling of Free-Form Surfaces

Table 1

Pseudocode for milling force prediction algorithm.

Input
	Cutting conditions	ap, ae, n, fz, θst, θex
	Tool geometry	R, N, β0
		αz, αc
		Kts, Krs, Kas, Kte, Kre, Kae
		∆κ
		∆ang
Output
	Cutting force record	FX, FY, FZ
Variable:
φp = 2π/N		Interdental angle
		Axial microelement steps
	n = 360/∆ang	Angle rotation value in one cycle
	j = 1 to n	Calculate the cutting force value for the entire cycle
	Fx(j) = Fy(j) = Fz(j) = 0.0	Initialized cutting force value
	i = 1 to m	Calculate all cutting microcutting forces
		Lag angle
		Actual position angle of microelement
	Fx(j) = Fy(j) = Fz(j) = 0.0	Initialized cutting force value
	k = 1 to N	Calculate the cutting force of all cutting edges
		Cutter tooth k instantaneous position angle
		Remember current angle
	if	If the cutter edge microelement participates in cutting
		Chip thickness at this cutting point
		Calculate cutting edge length
		Calculate the chip width
		Calculate microcutting forces in tangential, radial, and axial directions
		Matrix transformation of tangential, radial, and axial microelement cutting forces is performed to obtain the cutting force in the tool coordinate system, and all microelement cutting forces are summed to obtain the total cutting force
	Else
	Next i
	Next j
		Cutting force
	Draw the cutting force in curve of one rotation of FX, FY, FZ, and F