A simulation system is developed in this paper, which deals with the geometry and mechanics of machining with ball-end milling cutters. The geometry of the workpiece, the cutter, and the cutter/workpiece engagement is modeled using a geometric simulation system. This module uses a commercial solid modeler (ACIS) as a geometric engine and automatically extracts the critical geometric information required for the physical simulation system. To calculate the instantaneous cutting forces, a new mechanistic force model is developed. This force model takes into account the variations of the cutting coefficients along the cutting edge, and considers the variations of the rake angle and the chip flow direction on the rake face. The calibration of the developed model is performed for half-immersion ball-end milling operation. The applicability of the developed system is verified experimentally for various up-hill angles. It is shown that as the up-hill angle increases, the ball-nose tip engagement decreases which in turn significantly affects the magnitude of the resultant forces. Also, lower cutting forces and powers are experienced if cutting with the vicinity of the tool tip is avoided.

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