Abstract: Precisely and reasonably modeling for milling process is the key to study milled surface topography. First of all, according to the basic hypothesis of linear elasticity, the force acting on the cutter and its deflection in milling process are both divided into two parts: the static and dynamic. Then, applying differential geometry theory, by considering the regenerative feedback in practical milling process, the dynamic milling force acting on the unit length of cutter is derived, so that a new kind of dynamic deflection model of cutter is established. Based on this model, a new set of efficient numerical simulation algorithm is presented. In the mean time, the static deflection of cutter is also formulated. Finally, the rationality of this model is shown by simulation instances.

Key words: End-mills, Flexible cutter, Milled surface topography, Milling process model, Regenerative feedback