Abstract: “In milling process, and when machining sculptured surfaces cutting forces are variables. Due to the continuous curvature variations of these surfaces abrupt variations in cutting forces are engender. The aim of this research work is to predict the milling forces along tool path during finishing of sculptured surfaces with flat end mills on 3-axis CNC milling machines, using a predictive mechanistic model of cutting forces and a geometric workpiece modeled with Dexels. The main steps of the proposed approach are: 1) approximation of the workpiece by Dexels, 2) milling simulation that consists to simulate the removal material between tools and workpiece by localization the contact regions and 3) cutting forces prediction.”

Keywords: Sculptured Surfaces, Dexel, Flat End Mill, Tool Envelope, Tool-workpiece Contact Regions, Mechanistic Forces Model