Date of Award

January 2014

Degree Type


Degree Name

Doctor of Philosophy (PhD)


Mechanical Engineering

First Advisor

Yung C Shin

Second Advisor

Hazim El-Mounayri

Committee Member 1

Jie Chen

Committee Member 2

Charles C Krousgrill


Prediction of machining forces involved in complex geometry can be valuable information for machine shops. This study presents a mechanistic cutting force simulation model for ball end milling processes, using ray casting and voxel representation methods used in 3D computer graphics field. Using this method, instantaneous uncut chip cross sectional areas can be extracted, which can be used in cutting pressure coefficient extraction and machining simulation including machining forces and geometry of the workpiece. The major advantage of the proposed scheme is that it can simulate milling processes with arbitrary cutting tool geometry on a workpiece with complex geometry, using an algorithm with constant time complexity. A series of cutting experiments were carried out to validate the model. A dynamic simulation has also been incorporated in the the model. A multi-degree of freedom nonlinear structural dynamic method is used to model the vibration. The dynamic model is validated through experiments with a chatter detection strategy. The model efficiently simulate and chatter and tool deflection resulting from vibration due to cutting forces. Industrial application of the model and impact to the business aspect, are also described.