Geometric simulation of ball end milling and application for the precise machining

This paper clarifies the geometric influence of tool orientation on the thickness of undeformed chip in ball end milling because the influence of tool orientations on machining accuracy has never been investigated. Not only the shape of undeformed chip but also its thickness varies according to the tool orientations. The authors developed the experimental method for measuring the machining error on inclined surface in any direction and the simulation method of hemi-ellipsoid cutting. The experimental and simulated results support the influence of tool orientations. Through the experimental results and the simulation, the relationship between the tool orientation and the machining error has been clarified. The influence of tool orientation and tool path on the machining error has been discussed too.