MITSUBISHI ELECTRIC RESEARCH LABORATORIES http://www.merl.com Modeling Cutting Forces for 5-Axis Machining of Sculptured Surfaces Boz, Y.; Erdim, H.; Lazoglu, I. TR2011-043 May 2011 Abstract 5-axis ball-end milling processes are used in various industries such as aerospace, automotive, die-mold and biomedical industries. 5-axis machining provides reduced cycle times and more accurate machining via reduction in machining setups, use of shorter tools due to improved tool accessibility. However, desired machining productivity and precision can be obtained by physical modeling of machining processes via appropriate selection of process parameters. In response to this gap in the industry this paper presents a cutting force model for 5-axis ball-end milling cutting force prediction. Cutter-workpiece engagement is extracted via developed solid modeler based engagement model. Simultaneous 5-axis milling tests are conducted on Al7075 workpiece material with a carbide cutting tool. Validation of the proposed model is performed for impeller hub roughing tool paths. Validation test proves that presented model is computationally efficient and cutting forces can be predicted reasonably well. The result of validation test and detailed comparison with the simulation are also presented in the paper. CIRP Conference on Modelling of Machining Operations This work may not be copied or reproduced in whole or in part for any commercial purpose. Permission to copy in whole or in part without payment of fee is granted for nonprofit educational and research purposes provided that all such whole or partial copies include the following: a notice that such copying is by permission of Mitsubishi Electric Research Laboratories, Inc.; an acknowledgment of the authors and individual contributions to the work; and all applicable portions of the copyright notice. Copying, reproduction, or republishing for any other purpose shall require a license with payment of fee to Mitsubishi Electric Research Laboratories, Inc. All rights reserved. Copyright c  Mitsubishi Electric Research Laboratories, Inc., 2011 201 Broadway, Cambridge, Massachusetts 02139