Modeling 3D surface milling process using a ball-end milling cutter

When machining a 3D surface with a variable curved profile, we will have to use a ball-end milling cutter. With this type of cutter, depending on the position of the tool’s contact with the machining surface, the size and direction of the cutting force, cutting speed, cutting temperature, etc. will be different. The cutting speed varies from maximum to zero at the tip, so in the vicinity of the workpiece material is not cut but destroyed by deformation. This causes the deformation of the cutting tool to constantly change, greatly affecting the machining accuracy as well as the surface quality of the part. This error is a big problem for mechanical manufacturers because there are no specific studies so that they can make appropriate adjustments to the process of compiling the processing program. Therefore, there should be further studies on deformation of cutting tools. The research method is to use mathematical tools and calculation software to establish the relationship between shear force, surface roughness, transform the cutting tool’s position with technological parameters and machining surface geometry parameters. The paper focuses on building the cutting section model when milling 3D surfaces with the ball-end milling cutters. Simultaneously assess the parameters of cutting force and machining surface error when milling the 3D surface with a milling cutter.