A new analytical ICCE and force prediction model for wide-row machining of free-form surface

Cutting force is the most intuitive reflection of various influencing factors in the milling process, which is important for improving machining quality and efficiency. For the wide-row milling with flat-end mill of free-form surface, an analytical in-cut cutting edge (ICCE) algorithm is studied in detail, and overall cutting force model is further constructed. The cutter location points along tool path are discretized into small oblique planes. Taking the oblique plane machining as the new object, the relative position of flat-end mill and workpiece in five-axis machining is defined parametrically. By constructing a semi-enclosed space in which the cutting edge participates in cutting, the ICCE is directly obtained. By analyzing the cutting force of oblique plane, the cutting force model of free-form surface can be established by spatial coordinate transformation. The simulation and experiment have demonstrated the correctness and effectiveness of the proposed ICCE algorithm and force prediction model.