Simulating 5-Axis Milling with a Ball Nose Cutting Tool

5-axis milling has become widely used in industries where 3-Dimensional cutting is needed. The cutting cost is higher than using 3-axis milling due to the higher complexity of the machine tools. Although the literature describes research investigating the 5-axis cutting process experimentally, there is a lack of research focusing on modeling to the process. Existing models tend to simulate the process in step-wise fashion. In this paper a new model is presented which simulates the continuous process. The impact of this on the feed marks generated within the cusps is demonstrated.