Modeling and Simulation of Tool Engagement and Prediction of Process Forces in Milling

This work presents an advanced model for calculation of the microscopic contact conditions and prediction of the process forces in multi-axis milling. An investigation of the factors that influence the process forces with focus on finishing operations is presented in detail. Analytical abstractions to calculate the uncut chip geometry and the cutting forces are also presented. The result is a universal model and methodology for prediction of the process forces in complex milling operations.