A New Approach to Investigate the Formation Mechanism of the Not Modelable Cusps in 3-Axis Ball End Milling

The topography is one of the most important criteria to determine surface quality, and many researchers have studied its relationship with cutting parameters and machining errors. Many geometrical and numerical models are developed in this way. The geometric forms of the cusps and the scallop are extracted based on the trajectories of the teeth and their intersections with the part materials. The modeled topography is calculated by the mean of their measurements. In ball-end milling, the experimental results showed that the part material is crushed or ploughed near the cutter center, where the cutting speed is very low; this phenomenon can’t be captured by the developed models and decreases their accuracy. This work develops a new reflection on the cusps formation mechanism and gives the researchers a method for correcting the models used in computer-aided manufacturing programming to obtain an accurate part topography. The experimental test presented by (Batista et al. 2017) was used to confirm the new approach.