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Geometrical Modeling of Tool-Workpiece Contact Zone and Chip Formation in Finish Ball End Milling Process with Tool Inclination Angles

The tool-workpiece contact zone is an important issue in the ball end milling process. This paper investigated the effects of tool inclination angles on the tool-workpiece contact zone, and variations of the cutting section area and perimeter with the increasing tilt and lead angles were also analyzed by geometrical modeling and measurement method for ball end milling process. The appropriate tool inclination angles, which could avoid the extrusion and friction between tool tip and the uncut materials, shorten the loading time on the cutting flute, and decrease the maximum cutting forces, could be preferentially selected according to the distribution characteristics of the tool-workpiece contact zone and the variations of the cutting section area and perimeter corresponding to various tool postures.