A New Method for the Preparation of Cutting Edges via Grinding

2013 ◽  
Vol 769 ◽  
pp. 85-92 ◽  
Author(s):  
Christian Effgen ◽  
Bejamin Kirsch
Keyword(s):  
Tool Path ◽  
Cutting Edge ◽  
New Method ◽  
Grinding Wheel ◽  
Outer Diameter ◽  
Processing Times ◽  
Elastic Bond ◽  
End Mills ◽  
Grinding Machine ◽  
Milling Tools

In this paper, a new method for the preparation of cutting edges via grinding is presented. This method enables the manufacturing of the tool macro and micro geometry in one setup without reclamping, allowing improved flexibility, repeatability and accuracy at reduced processing times. This new method is path controlled using a special elastic bond for the grinding wheels. By using elastic bond, a rounded cutting edge instead of undesired chamfers can be achieved, as the bond nestles around the cutting edge and elastically deforms. The elastic bond is specified by the grain concentration and its basic hardness. Besides the specifications of the bond, the process kinematics highly influences the properties of the cutting edge. The kinematics is a combination of the tool path (machining strategy) and the grinding wheel geometry. The presented experiments include the examination of three different kinematics using three different grinding wheel geometries, FEPA 1A1, 1V1 and 4A2. For each kinematics, three different grain concentrations and three degrees of basic bond hardness were tested, resulting in a complete amount of 27 parameter combinations. The outer diameter cutting edges of cemented carbide milling tools (end mills) were prepared in a 5-axis tool grinding machine. The shape and quality of the achieved cutting edge rounding was qualitatively evaluated by means of scanning electron microscopy (SEM).

scholarly journals Influence of End Mill Manufacturing on Cutting Edge Quality and Wear Behavior

2021 ◽  
Vol 5 (3) ◽  
pp. 77
Author(s):  
Berend Denkena ◽  
Alexander Krödel-Worbes ◽  
Sascha Beblein ◽  
Markus Hein
Keyword(s):  
Wear Behavior ◽  
Cutting Edge ◽  
End Mills ◽  
Edge Quality ◽  
Manufacturing Process Chain ◽  
The Individual ◽  
Application Specific ◽  
Milling Tools ◽  
Edge Preparation

One of the decisive factors for the performance of milling tools is the quality of the cutting edge. The latter results from the process control of the individual steps along the tool manufacturing process chain, which generally includes the sintering or pressing of the blanks, grinding, cutting edge preparation, and coating of the tools. However, the targeted and application-specific design of the process steps in terms of high economic efficiency is currently limited by a lack of knowledge regarding the influence of the corresponding process parameters on the resulting cutting edge quality. In addition, there is a lack of suitable parameters that adequately represent the characteristics of the cutting edge microtopography. This publication therefore investigates the influence of manufacturing processes on cutting edge quality and wear behavior of end mills. On this basis, different characterization parameters for the cutting edge quality are derived and evaluated with regard to their ability to predict the wear behavior.

New method for detecting active infeed of cutting edge of end mills

2021 ◽  
Author(s):  
Petr M. Pivkin ◽  
Vladimir A. Grechishnikov ◽  
Ilya V. Minin ◽  
Mikhail Mosyanov ◽  
Alexsey B. Nadykto
Keyword(s):  
Cutting Edge ◽  
New Method ◽  
End Mills

scholarly journals METHOD FOR CALCULATING CUTTING FORCES BY MODELING CAD WITH A SYSTEM OF GEOMETRIC CUTTING PARAMETERS WITH RADIAL MILLS

2021 ◽  
pp. 50-57
Author(s):  
Alexander Leshchenko
Keyword(s):  
Cutting Forces ◽  
Tool Path ◽  
Cutting Parameters ◽  
Cutting Edge ◽  
Software Module ◽  
Power Characteristics ◽  
Cad System ◽  
Shaping Process ◽  
End Mills ◽  
Processing Zone

The accuracy of processing surfaces of a complex profile largely depends on the selected processing strategy, which will allow creating the same, within certain limits, power characteristics of the shaping process at the intervals of the programmed tool path. In this case, it becomes possible to include tuning modules in programs for CNC machines that form vector values of corrections in certain areas, as reactors for elastic deformations of the cutting process. Therefore, it is especially important to know the modulus and direction of the resulting cutting force vector, which does not necessarily coincide with the feed direction. The purpose of this work is to build a method for calculating cutting forces by modeling the geometric parameters of a cut with a CAD system, a cutter with a nonlinear generatrix. Solid modeling of the process is based on the Boolean operations of "intersection" and "subtraction" of 3D objects: the teeth of a radius cutter with a helical cutting edge and a workpiece "moving" at a feed rate. The tool for the implementation of this method is a software module created on the basis of API functions, the input data for which are: a 3D tool and a workpiece, the equation of the trajectory of its movement and the parameters of the infeed movement. Targeting API properties, the application makes it possible to simulate various trajectories, helical or trochoidal, when machining complex surfaces. In the future, it is possible to take into account the plastic deformation processes in the chip formation zone in the model by connecting external modules. In the course of the conducted research on milling with radial end mills with a helical cutting edge, when two or more teeth are within the arc of contact, it was determined by 3D modeling how much thickness and width the layer cuts off each of the teeth during the feed per revolution. Consequently, in the process of shaping, normal and tangential cutting forces, which are different in direction and modulus, are present as a function of the angle of rotation of the cutter. Therefore, the concept of "circumferential force on the cutter", accepted in the theory of cutting, as a certain constant component of the process, can introduce an error when considering the causes of the excitation mechanism of vibrations of different nature that arise in the processing zone.

5-Axis Control Dexterous Ultraprecision Micromilling of Ruled Surface with Side Cutting Edge

2012 ◽  
Vol 516 ◽  
pp. 176-180
Author(s):  
Ryo Nishiyama ◽  
Keiichi Nakamoto ◽  
Tohru Ishida ◽  
Yoshimi Takeuchi
Keyword(s):  
Tool Path ◽  
Tool Path Generation ◽  
Ruled Surface ◽  
Cutting Edge ◽  
Work Piece ◽  
End Mill ◽  
Ball End Mill ◽  
Tool Paths ◽  
End Mills ◽  
Quality Surface

This study deals with 5-axis control tool path generation to create microshapes dexterously and efficiently, while maintaining quality. Concerning 5-axis control machining, the use of ball end mills is generally employed. However, this method needs a lot of time to obtain high quality surface. To solve this problem, a side cutting edge of the ball end mill is positively utilized with its parallel to the ruled surface. Therefore, a new CAM system is developed to detect the surface to be machined with the side cutting edge, and to generate collision-free tool paths between the tool and the work piece. The effectiveness of the developed CAM system is experimentally confirmed by creating a tiny Möbius ring.

scholarly journals Process Related Characteristic-Based Topography Evaluation of Wear Conditions On Grinding Wheels

2021 ◽  
Author(s):  
Maikel Strug ◽  
Berend Denkena ◽  
Bernd Breidenstein ◽  
Alexander Krödel-Worbes
Keyword(s):  
Evaluation Method ◽  
Process Efficiency ◽  
Grinding Wheel ◽  
The Novel ◽  
Grinding Wheels ◽  
Dressing Tool ◽  
Grinding Tool ◽  
Grinding Machine ◽  
Related Characteristic ◽  
Milling Tools

Abstract Non-productive auxiliary processes affect the single part and small badge production of milling tools. The key production process grinding is inevitably linked to the auxiliary conditioning process. The time demand of those process steps decreases the overall productivity of the manufacturing process. However, today the machine operator decides on conditioning cycles individually by the use of experience. Until today, there is no objective data based approach available that supports the initiation of these conditioning processes or the adaption of the grinding process itself in order to improve its process efficiency. For this purpose, a process related topography evaluation method of the grinding wheel surface is developed within this study. For the measurement an optical method based on laser triangulation is used. The measurement system is implemented into a common tool grinding machine tool. In addition, characteristic topography values are defined that show the wear conditions of the grinding tool. Moreover, the data is summarized in a database of wear conditions. The developed measurement method can save grinding and dressing tool resources, process times and minimizes scrap parts. In addition, an adaptation of the process and a targeted launch of auxiliary processes can be enabled. The novel characteristic-based topography measurement creates the opportunity to enhance the tool life of the grinding wheels up to 30 % without losing productivity.

The New Method in Scraping the Back Off Surface of Side Edge of the Carbide Hob

2011 ◽  
Vol 694 ◽  
pp. 754-759
Author(s):  
Hu Ran Liu
Keyword(s):  
Contact Condition ◽  
Cutting Edge ◽  
New Method ◽  
Grinding Wheel ◽  
Side Edge ◽  
Nc Grinding

The paper determines the shape of grinding wheel by the contact condition, not by the cutting edges, and introduced the NC grinding. After regrinding the cutting edge has at least 2 points coincided with the theoretical edge, even after regrinding for many times. So that increased the length of regrinding of the hob.

Development of Tool Fabrication CAD/CAM for Conicoid End Mill

2007 ◽  
Vol 1 (2) ◽  
pp. 128-135 ◽  
Author(s):  
Koichi Morishige ◽  
◽  
Shingo Ishizuka ◽  
Yoshimi Takeuchi ◽  
◽  
...  
Keyword(s):  
Cutting Edge ◽  
Machining Accuracy ◽  
Data Generation ◽  
3D Cad ◽  
Shape Precision ◽  
Cad Cam ◽  
End Mills ◽  
Tool Fabrication ◽  
Nc Data ◽  
Grinding Machine

This study deals with new practical fabrication of end mills based on 3D-CAD/CAM. End mills with arbitrary shapes generally difficult to produce are useful in upgrading machining accuracy and efficiency. Our tool fabrication CAD/CAM potentially produces end mills with arbitrarily shaped cutting edge. In order to make them practical, we developed a way to design the cutting edge shape and NC data generation for a 5-axis controlled tool grinding machine. The resulting system enables produces practical, arbitrarily shaped end mills with shape precision comparable to their commercially available counterparts.

Calculation of Effective Ground Depth of Cut by Means of Grinding Process Model

2011 ◽  
Vol 496 ◽  
pp. 7-12 ◽  
Author(s):  
Takazo Yamada ◽  
Michael N. Morgan ◽  
Hwa Soo Lee ◽  
Kohichi Miura
Keyword(s):  
Process Model ◽  
Ground Surface ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Wheel Wear ◽  
Elastic Deformations ◽  
Proposed Model ◽  
Effective Depth ◽  
Grinding Machine

In order to obtain the effective depth of cut on the ground surface, a new grinding process model taking into account thermal expansions of the grinding wheel and the workpiece, elastic deformations of the grinding machine, the grinding wheel and the workpiece and the wheel wear was proposed. Using proposed model, the effective depth of cut was calculated using measured results of the applied depth of cut and the normal grinding force.

Influence of Tooth Errors and Truing Principles of Grinding Wheel Abrasion for Machining Arc Enveloping Worm

2013 ◽  
Vol 652-654 ◽  
pp. 2153-2158
Author(s):  
Wu Ji Jiang ◽  
Jing Wei
Keyword(s):  
Mathematical Model ◽  
Case Studies ◽  
High Precision ◽  
High Performance ◽  
New Method ◽  
Grinding Wheel ◽  
Grinding Process ◽  
The Mathematical Model

Controlling the tooth errors induced by the variation of diameter of grinding wheel is the key problem in the process of ZC1 worm grinding. In this paper, the influence of tooth errors by d1, m and z1 as the grinding wheel diameter changes are analyzed based on the mathematical model of the grinding process. A new mathematical model and truing principle for the grinding wheel of ZC1 worm is presented. The shape grinding wheel truing of ZC1 worm is carried out according to the model. The validity and feasibility of the mathematical model is proved by case studies. The mathematical model presented in this paper provides a new method for reducing the tooth errors of ZC1 worm and it can meet the high-performance and high-precision requirements of ZC1 worm grinding.

Tool Path Generation for Five-Axis Controlled Machining of Free-Form Surface Using Barrel Tool: Control of Contact Point on Cutting Edge

2020 ◽  
Author(s):  
Tomonobu Suzuki ◽  
Koichi Morishige
Keyword(s):  
Tool Path ◽  
Contact Point ◽  
Cutting Edge ◽  
Free Form ◽  
End Mill ◽  
Ball End Mill ◽  
Surface Machining ◽  
Free Form Surface ◽  
The Cost ◽  
Five Axis

Abstract This study aimed to improve the efficiency of free-form surface machining by using a five-axis controlled machine tool and a barrel tool. The barrel tool has cutting edges, with curvature smaller than the radius, increasing the pick feed width compared with a conventional ball end mill of the same tool radius. As a result, the machining efficiency can be improved; however, the cost of the barrel tool is high and difficult to reground. In this study, a method to obtain the cutting points that make the cusp height below the target value is proposed. Moreover, a method to improve the tool life by continuously and uniformly changing the contact point on the cutting edge is proposed. The usefulness of the developed method is confirmed through machining simulations.

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