Implementation of analytical boundary simulation method for cutting force prediction model in five-axis milling

A simulation system was developed that deals with cut geometry and machining forces when a toroidal cutter is used during semifinishing in five-axis milling. The cut geometry was calculated using an analytical method called analytical boundary simulation (ABS). ABS was implemented to calculate the cut geometry when the machining used an inclination angle and a screw angle. The effect of tool orientation on the cut geometry was analyzed. The accuracy of the proposed method was verified by comparing the cut lengths calculated using ABS with cuts obtained experimentally. The result indicated that the method was accurate. ABS was subsequently applied to support a cutting force prediction model. A validation test showed that there was a good agreement with the cutting force generated experimentally.