Analysis of Surface Generating Mechanism of Ball End Mill Based on Deflection by FEM

This paper deals with the analysis of the surface generating mechanism of a ball end mill based on deflection. The FEM model of a ball end mill is made out and the cutter deflection due to cutting force is calculated using the model and the cutting edge position is predicted using the behavior of cutting force obtained by the cutting tests and cutting area calculated by 3D-CAD. The shape of the machined surface is predicted by summation of cutting edge positions which are obtained by the cutter deflection and the cutter rotation during machining. The predicted surface is almost coincident to the experimental shape, so the method of calculation for the machined shape is verified.