An optimized milling force prediction method for multi-axis ball-end finish milling

Abstract By accurately predicting milling force in finish milling, simulation of the process can be effectively conducted, followed by provision effective recommendations on optimization machining parameters. The prediction ball-end poses a significant challenge due to influence cutter workpiece engagement (CWE) calculation and cutting coefficient identification. This paper proposes precise approach for force, which involves an improved method CWE optimized identification coefficients based mechanistic model. In CWE, considering dynamic change undeformed slice thickness boundary is proposed. Furthermore, incorporating interference signal removal multiple nonlinear regression fitting methods utilized Subsequently, resulting validated through comparison with measurements demonstrates accuracy exceeding 94%. conclusion drawn that proposed multi-axis exhibits high its predictions.