Abstract: “Optimization of ball end milling processes has been an area of great interest, on the grounds that such processes are extensively used for precision and high-efficiency machining of freeform and complex surfaces. The selection of optimal cutting conditions, involved in such processes, can be accomplished by utilizing models that simulate the kinematics of the milling process, therefore allow the analytical prediction of the produced surface topomorphy and quality. The present study introduces a model developed for the simulation of milling processes, integrated in a commercial CAD software. Furthermore, several ball-end milling of Al7075-T6 experiments were carried out under various cutting conditions, so as to verify the completeness and accuracy of the above mentioned model, through the comparison of the predicted and the machined surface. According to the validation outcomes, the developed model demonstrates high computational efficiency.”

Keywords: ball-end milling, cad-based simulation, surface topomorphy