Modeling of instantaneous uncut chip thickness in 5-AXIS flank milling considering cutter runout

In the five-axis flank milling, the calculation process of the instantaneous uncut chip thickness (IUCT) is complicated because of the motion of the two additional rotational axes. To focus on the problem that the IUCT prediction in five-axis milling is inefficient, an IUCT calculation method considering the cutter runout effect is proposed in this paper. First, the geometry model of the cutting tool is established, and the coordinate of a cutting edge point can be obtained. Then, based on the geometrical relationship of two adjacent tool positions, the analytical solution of the IUCT can be derived. Finally, the simulation of the proposed method is carried out to validate the practicability of the model. The results show that the proposed model can achieve good efficiency and acceptable accuracy and be applied to milling force prediction.