Dynamic simulation and experimental study of cutting force by rake angle of multi-axis high-speed ball-end milling tool

Aluminum alloy high-speed milling is commonly utilized in the aircraft, aerospace, mold, and other sectors, and its cutting force characteristics will have an important impact on the final machining quality of parts. The cutting force characteristics of high-speed milling of an aluminum alloy workpiece using a ball end milling cutter were investigated in this research. A three-dimensional finite element dynamic simulation model was developed for the high-speed milling of ball-end milling cutters. Firstly, the benefit of tool axis vector inclination angle in multi-axis machining was discussed, and the inclination angle of the tool axis vector in multi-axis machining was characterized more precisely. The three-dimensional model of the ball-end milling cutter was established according to the actual machining, and in order to simulate the machining process, it was put into a finite element analysis system. The rotation and intermittent cutting of the tool were considered in the simulation process, which was in good agreement with the actual machining process. In a finite element simulation environment, the cutting force under 25 groups of rake inclination angles was simulated, and verification milling tests on a five-axis machine were carried out. According to the results, the general trend of the maximum cutting force in all directions was in good agreement with the experimental results. Finally, the range of the rake inclination angle with less cutting force and more stable cutting force in multi-axis machining was given. The results also confirmed the reliability of the simulation results, and provided a reference for the finite element simulation of other metal cutting processes.