A study on the effect of technology parameters on 3D geometric surface parameters in ball-end milling process

Machining 3D surfaces with variable curvature profiles, the cutting tool, which is a ball-end milling tool, must be used. With this type of tool, depending on the position of the tool’s contact with the machining surface, the magnitude as well as the direction of cutting force, cutting speed, cutting temperature … are different. 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 leads to the deformation of the cutting tool also changes continuously, 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 has not been any specific research to adjust appropriately for the process of compiling processing programs. Therefore, there should be further studies on deformation of cutting tools. The paper focuses on modeling the cutting area, shear force, geometric error and roughness of machining surface when milling 3D surface with ball-end milling cutters. In this study, using methods such as experimental testing, regression and simulation to develop regression equations to evaluate the influence of technological parameters on shear forces, surface roughness and 3D surface geometry error.