Investigation of the Mechanism of Cutting by the Ball End Mill Tip and Its Influences on the Surface Topography and the Cutting Force

The modeling of the cutting process is one of the important roads to optimize cutting parameters through computer-aided manufacturing simulations. However, many models, whether analytical, numerical, or geometrical, are plagued by inaccuracies, consistently exhibiting a percentage of errors when compared to experimental tests. This paper investigates and analyzes certain interpretations and observations to illustrate inaccuracies in the existing models for roughness, topography, and cutting forces, specifically in the context of 3-axis ball end milling. An approach is proposed to enhance the accuracy of predicting these models.