Prediction of Surface in Machining by Flat and Spherical Surface Tools

In this paper, the profile of surfaces machined using end mills with flat and ball end tools in modeled. The real kinematics of the tool motion, the static deflection and the run out of the tool are included in the model. The cutting forces are calculated using a semi-empirical method based on orthogonal to oblique conversion of cutting coefficients. The thickness of the uncut chip is used as the critical parameter affected by the tool run out. Based on the above model, the final profile of the surface is generated and compared with existing experimental results