Five-Axis CNC Tool Grinding: Part I—Rake Face Grinding

ASME 2011 International Manufacturing Science and Engineering Conference, Volume 1 ◽

10.1115/msec2011-50014 ◽

2011 ◽

Cited By ~ 2

Author(s):

Mahmoud M. Rababah ◽

Zezhong C. Chen

Keyword(s):

Rake Angle ◽

Grinding Process ◽

Rake Face ◽

End Mill ◽

Grinding Wheels ◽

Robust Algorithm ◽

Geometric Representations ◽

Five Axis ◽

Face Grinding ◽

Tool Grinding

Grinding the helical surfaces in end-mill cutters using two-axis CNC machines is well investigated in literature. However, the grinding wheels do not have explicit geometric representations and the produced helical angles differ from the designed values. Moreover, to the best knowledge of the authors, no reliable and robust algorithm exists to grind generic shape cutters with constant normal rake angles. Thus, the first part of this work introduces a five-axis grinding process that keeps the normal rake angle constant along the rake face. The parameters that affect the shape of the tool flutes are also analyzed and studied in this part. These parameters are then optimized in the second part to obtain optimum wheel shapes grinding the tool flutes along optimum paths. Overall, the grinding process proposed grinds the tool flutes with close matching to the designed ones and replaces the complex wheel shapes commonly used by simple prismatic ones.

Download Full-text

A Generalized and Efficient Approach for Accurate Five-Axis Flute Grinding of Cylindrical End-Mills

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4037420 ◽

2017 ◽

Vol 140 (1) ◽

Cited By ~ 3

Author(s):

Lei Ren ◽

Shilong Wang ◽

Lili Yi

Keyword(s):

Singular Points ◽

Grinding Process ◽

Core Radius ◽

End Mill ◽

New Approach ◽

Original Algorithm ◽

Efficient Approach ◽

Computer Aided ◽

End Mills ◽

Five Axis

Wheel position (including wheel location and orientation) in the flute grinding process of an end-mill determines the ground flute's geometric parameters, i.e., rake angle, core radius, and flute width. Current technologies for calculating the wheel position to guarantee the three parameters' accuracy are either time-consuming or only applicable to the grinding wheels with singular points. In order to cope with this problem, this paper presents a generalized and efficient approach for determining the wheel position accurately in five-axis flute grinding of cylindrical end-mills. A new analytic expression of the wheel location is derived and an original algorithm is developed to search for the required wheel position. This approach can apply not only to the wheels with fillets but also to the wheels with singular points. Simulation examples are provided to validate the new approach and compared with the results from other literature. Besides the ability to determine the wheel position, the new approach can evaluate extrema of the core radius and flute width that a specified wheel can generate. Owing to the evaluated extrema, automatic 1V1 wheel customization according to the designed flute is realized in this paper. This work can improve the efficiency and automation degree of the flute grinding process and lay a good foundation for the development of a comprehensive computer-aided design and computer-aided manufacturing system for end-mill manufacturing.

Download Full-text

Effect of Grinding Wheel Diameter Change on Geometrical Parameters of Ball-Nose End Mill

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.97-101.4527 ◽

2010 ◽

Vol 97-101 ◽

pp. 4527-4529 ◽

Cited By ~ 1

Author(s):

Lin He ◽

L.M. Sun ◽

Xian Feng Zhao ◽

Jun Wang

Keyword(s):

Visual Basic ◽

Rake Angle ◽

Simulation System ◽

Grinding Wheel ◽

Geometrical Parameters ◽

Rake Face ◽

End Mill ◽

Visual Basic For Applications ◽

Grinding Simulation ◽

Diameter Change

The grinding simulation system of ball-nose end mill rake face is developed based on the four axis linkage mathematical model using Solidworks and Visual Basic for Applications (VBA). Effects of grinding wheel diameter change due to wear on geometrical parameters of ball-nose end mill, such as ball-nose rake angle, column rake angle and edge strip width are investigated.

Download Full-text

Research and Development of Four Axis Linkage Grinding Simulation System of Ball-Nose End Mill

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.443.314 ◽

2010 ◽

Vol 443 ◽

pp. 314-317

Author(s):

Lin He ◽

Xian Feng Zhao ◽

Hong Yan Shi ◽

Jun Wang

Keyword(s):

Simulation System ◽

Rake Face ◽

End Mill ◽

Ball End Mill ◽

Nc Programming ◽

Solid Models ◽

Flank Face ◽

The Mathematical Model ◽

Face Grinding ◽

Grinding Simulation

The four axis linkage grinding simulation system of ball-nose end mill has be developed based on the mathematical model of four axis linkage grinding through establishing ball-nose end mill's parametrical database, constructing ball-nose end mill’s and grinding wheel's solid models in Solidworks, simulating the grinding processes of the rake face and flank face of ball-nose end mill based on Boolean operation, and automatic NC programming of rake face and flank face grinding. The results show the grinding simulation system can be used to manufacture ball end mill.

Download Full-text

An Automated and Accurate CNC Programming Approach to Five-Axis Flute Grinding of Cylindrical End-Mills Using the Direct Method

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4023271 ◽

2013 ◽

Vol 135 (1) ◽

Cited By ~ 14

Author(s):

Mahmoud M. Rababah ◽

Zezhong C. Chen

Keyword(s):

Direct Method ◽

Rake Angle ◽

Programming Approach ◽

Rake Face ◽

Core Radius ◽

End Mill ◽

The Core ◽

Computer Aided ◽

Cnc Programming ◽

End Mills

In solid carbide end-mills, the flutes significantly affect the tool's cutting performance and life, and the core radius mainly affects the tool's rigidity. The current CNC programming techniques can correctly determine the orientation of the wheel so that it grinds the rake face with the specified rake angle; however, it cannot accurately determine the wheel location for the direct method and, consequently, the desired core radius is not guaranteed. To address this problem, a new CNC programming approach is proposed to accurately calculate the wheel orientation and location (WOL) in 5-axis grinding of the cylindrical end-mill flutes. In this work, a new concept of 5-axis CNC grinding—effective grinding edge (EGE)—is first proposed to represent the instantaneous grinding edge of the wheel, and the parametric equations of the effective grinding edge are formulated. The wheel orientation and location in 5-axis flute grinding are calculated automatically and accurately so that the rake angle of the rake face and the core radius are ensured. The new approach is verified with several examples in this work. Therefore, it can improve the end-mill quality and lays a good foundation for the computer-aided design/computer-aided engineering/computer-aided manufacturing (CAD/CAE/CAM) of end-mills.

Download Full-text

The Mathematic Model of End Mill’s Rake Face Based on the Fillet and Two Attitude Angles of Grinding Wheel

Materials Science Forum ◽

10.4028/www.scientific.net/msf.800-801.249 ◽

2014 ◽

Vol 800-801 ◽

pp. 249-253 ◽

Cited By ~ 1

Author(s):

Xian Feng Zhao ◽

Hong Yan Shi ◽

Lin He

Keyword(s):

Three Dimensional ◽

Mathematic Model ◽

Grinding Wheel ◽

Grinding Process ◽

Rake Face ◽

End Mill ◽

Precise Description ◽

Set Up

The mathematic model of rake face was set up for precise description on the rake face of end mill in grinding process, with its basis on the fillet of grinding wheel with six axes linkage movement and two attitude angles. The sectional drawing of rake face and three-dimensional entity were drawn based on the mathematic model in SolidWorks. At the same time, the discrete entity of rake face also set up based on the Boolean calculation. The sectional drawing of mathematic model and the discrete entity tallies with each other perfectly, which indicates the correctness about the mathematic model of rake face.

Download Full-text

The Influence of the Grinding Wheel Parameters on the Spiral Groove Parameters of the End Mill

Materials Science Forum ◽

10.4028/www.scientific.net/msf.836-837.139 ◽

2016 ◽

Vol 836-837 ◽

pp. 139-146

Author(s):

Xian Feng Zhao ◽

Hong Yan Shi ◽

Lin He

Keyword(s):

Mathematical Model ◽

Cone Angle ◽

Rake Angle ◽

Opening Angle ◽

Grinding Wheel ◽

Grinding Process ◽

End Mill ◽

Spiral Groove ◽

Wheel Radius ◽

Weak Influence

Inorder to analyze the influence of the grinding wheel parameters on the spiralgroove parameters in the grinding process of spiral groove, this paper analyses indetail the influence of grinding wheel radius, fillet radius and grinding wheelcone angle on the rake angle and the opening angle of the spiral groove basedon the spiral groove mathematical model of the end mill. And two polynomial werefitted between the grinding wheel fillet and the rake angle of spiral groove. Studieshave shown that: when the wheel attitude angle remains unchanged, the fillet ofgrinding wheel influence the rake angleand opening angle of spiral groove significantly; the cone angle of grindingwheel affects the opening angle largely; the radius and cone angle of grindingwheel have the weak influence on the rake angle of spiral groove.

Download Full-text

Peculiarities of the Grinding Process of a Gear Hob Helical Rake Face

Acta Universitatis Sapientiae Electrical and Mechanical Engineering ◽

10.2478/auseme-2021-0004 ◽

2021 ◽

Vol 13 (1) ◽

pp. 39-51

Author(s):

Norbert Hodgyai ◽

Márton Máté ◽

Ferenc Tolvaly-Roşca ◽

Mircea Viorel Drăgoi

Keyword(s):

Mathematical Model ◽

Grinding Process ◽

Rake Face ◽

Cad Modeling ◽

The Mathematical Model ◽

Face Grinding

Abstract This paper presents a study regarding the gear hob’s rake face grinding possibilities and its consequences. A simple theoretical lined surface is considered. The mathematical model of the reciprocate meshing of surfaces was applied. It was proven that the proposed form of the rake face cannot be obtained because an undercut of inacceptable extent occurs. It is also proven and sustained by CAD modeling that using a simplified, flat grinding disk, the undercut is avoided, but the phenomenon of transection appears.

Download Full-text

A New Approach to Five-Axis CNC Flute Grinding of Solid End-Mills

Materials Science Forum ◽

10.4028/www.scientific.net/msf.723.421 ◽

2012 ◽

Vol 723 ◽

pp. 421-432 ◽

Cited By ~ 2

Author(s):

Mahmoud M. Rababah ◽

Ze Zhong C. Chen ◽

Li Ming Wang

Keyword(s):

Cutting Tools ◽

Grinding Wheel ◽

Rake Face ◽

Ball End Mill ◽

New Approach ◽

Minor Radius ◽

End Mills ◽

Tool Strength ◽

Five Axis ◽

Face Grinding

The traditional cutting tools grinding reveals inexact tool flutes that altered the tool strength and affect the chip evacuation capabilities. Moreover, the normal rake angles are neither exact nor varying smoothly on the rake face along the cutting edge. Adopting the rake face grinding process, the wheel shape and path are optimized using GODLIKE scheme in order to grind the tool flutes with exact helical and normal rake angles while keeping close matching to the designed flutes. A tapered ball-end mill is considered in this study due to its extensive role in five-axis sculpture surfaces machining. With this approach proposed, a simple grinding wheel replaces the complex wheels commonly used, and the deviation between the designed and the generated flutes reveals less than 4 % of the tool minor radius. Beside all, a relationship between the radial and the normal rake angles are established.

Download Full-text