Research on the influence of tool inclination angle and surface curvature on cutting force of ball-end milling mold steel S136

Ball-end milling is often used to machine molds with curved surfaces. The quality of the machined surface and the accuracy of the final product are directly affected by the cutting force. Correctly establishing the cutting force model for ball-end milling of curved surfaces is crucial for parameter selection and the production of high-precision molds. In the present paper, a ball-end milling force model considered the influence of the inclination between the ball-end mill and the machined surface as well as the machined surface curvature was proposed. The uncut area was discretized, and the local cutting edge was substituted into the classic oblique cutting model. The shear force and edge force caused by the edge during the milling process were considered, and the components of each cutting edge element were analytically calculated. Experiments focused on ball-end milling variable surfaces of S136 were conducted. The results demonstrate a substantial impact of the inclination angle on cutting forces, and the validity of the model has been verified.