Serbest yüzey geometrili parçalarin 5 eksen küresel frezelenmesinde kesme kuvvetlerinin modellenmesi

5-axis milling processes are used widely in various industries such as aerospace, die-mold and biomedical industries where surface quality and integrity is important and the production tolerances are very tight. Therefore, improving surface quality and integrity without sacrificing productivity is crucial in these industries. Improvements in CAD/CAM, cutting tool and the machine tool technologies allow the production of high precision parts with less cycle times. In order to obtain desired quality and productivity, process parameters such as feedrate, spindle speed, axial and radial depth of cut have to be selected appropriately. In general, these parameters are selected conservatively, most of the time arbitrarily, in order to prevent workpiece, cutter or the machine to be damaged. Consequently, this selection criterion is based on engineering expertise or trial and error methods. Therefore virtual machining simulation for milling processes is an increasing demand before the production of the free-form surfaces.In this thesis, virtual machining simulation model for the simulation of cutting forces in 5-axis ball-end milling of free-form surfaces is presented.5-axis milling kinematics differs from the 3-axis milling. For this reason, modeling of 5-axis machine tool kinematics is introduced and a generic post-processor with variable feedrate is developed. A virtual machine simulation model, which is capable of simulating machine tool movements from the NC code, is also presented.Cutting forces in machining is determined by extracting the Cutter-Workpiece Engagement (CWE) from the in-process workpiece. A discrete method (Three-Orthogonal Dexelfield) of obtaining CWE maps for 5-axis ball-end milling is developed. The results of the Three-Orthogonal Dexelfield method is compared with the solid-modeler based CWE calculation method.A cutting force prediction model for 5-axis ball-end milling is developed. Cutting force modeling is performed in the fixed coordinate frame (for table type dynamometer) and in the rotating coordinate frame (rotating coordinate dynamometer). A modular approach is developed where different cutter and workpiece geometries and tool motions can be incorporated into the model without additional analysis. Several validation tests are presented in the study and these validation tests demonstrate that presented cutter-workpiece engagement model is accurate and force predictions are in good agreement with the measured data.