End Milling Force Algorithms for CAD Systems

This paper presents an efficient milling mechanics simulation system for use with solid modeller based tool path generation algorithms. The technique provides computationally efficient cutting force predictions for end milling of general part shapes. First, the part is described using the Constructive Solid Geometry representation scheme. Along the cutter path the tool-workpiece interaction is represented using immersion are segments obtained by intersecting the cutter with each part feature. Next, a cutting mechanics model is used to predict the instantaneous, average and peak forces, and maximum cutter deflections left on the finished part surface. By separating the cutter constants from the part geometry, the model allows automatic feed rate scheduling to satisfy end milling constraints. Verification of the method by both simulation and experiment is included.