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

2013 ◽  
Vol 135 (1) ◽  
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.

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

2017 ◽  
Vol 140 (1) ◽  
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.

A New Method for Determination of Wheel Location in Machining Helical Flute of End Mill

2016 ◽  
Vol 138 (11) ◽  
Author(s):  
Van-Hien Nguyen ◽  
Sung-Lim Ko
Keyword(s):  
Computer Aided Design ◽  
Search Algorithm ◽  
Rake Angle ◽  
Design Parameters ◽  
End Mill ◽  
Axis Orientation ◽  
Computer Aided ◽  
End Mills ◽  
Helical Flute ◽  
Setting Parameters

This paper presents a mathematical model to find the wheel location in grinding a given helical flute of an end mill. Two new setting parameters are introduced to define the relative wheel location in workpiece coordinates. This model allows the wheel-axis orientation be expressed explicitly as a function of the design factors and machine setting parameters. By utilizing this explicit form of the wheel orientation and analyzing the influence of setting parameters on design parameters, a new efficient search algorithm is proposed, and the performance shows that the required wheel location is found within 1.5 s to machine a given flute profile. Moreover, the rake angle can be produced more precisely compared with the conventional methods, which have been used with approximations. A comprehensive development of the software for designing and grinding the helical flute of the end mill is presented, which provides a technology and good foundation for the development of a computer-aided design and computer-aided manufacturing (CAD/CAM) system for manufacturing end mills. The results of the experiment, simulation, and design are compared in order to verify of the proposed method.

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

2011 ◽  
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.

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

2010 ◽  
Vol 97-101 ◽  
pp. 4527-4529 ◽  
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.

Study on Helical Groove and Circumferential Cutting Edge Machining Simulation of End Mill

2013 ◽  
Vol 589-590 ◽  
pp. 351-356
Author(s):  
Guo Chao Li ◽  
Jie Sun ◽  
Jian Feng Li ◽  
Qing Chun Xiong
Keyword(s):  
3D Model ◽  
Rake Angle ◽  
Cutting Edge ◽  
Machining Simulation ◽  
End Mill ◽  
Inner Radius ◽  
Helical Groove ◽  
End Mills ◽  
Wheel Profile ◽  
The Mathematical Model

A purely analytical method, based on the meshing theory, is presented to establish the exact helical groove and circumferential cutting edge model of end mills, for the solution of its low design precision and efficiency problems. Firstly, a coordinate system to represent the relative space position relations between grinding wheels and end mills is built and the mathematical model of the helical groove is precisely calculated with a given wheel profile and relative movements between the wheel and the workpiece. Then, the rake angle, inner radius and wheel positions of machining the clearance faces is computed. Finally, a 3D model of the end mill is generated by using OpenGL.

Investigation of cBN Electroplated End-Mill Shape for CFRP Machining

2016 ◽  
Vol 874 ◽  
pp. 463-468
Author(s):  
Tatsuya Furuki ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama ◽  
Keiji Ogawa ◽  
Kiyofumi Inaba ◽  
...  
Keyword(s):  
High Efficiency ◽  
Cubic Boron Nitride ◽  
Rake Angle ◽  
Machining Process ◽  
End Mill ◽  
Carbon Fiber Reinforced Plastics ◽  
Reinforced Plastics ◽  
End Mills ◽  
High Thermal Resistance ◽  
Fiber Reinforced Plastics

Currently, carbon fiber reinforced plastics (CFRP) are being increasingly adopted in various fields. Thus, machining CFRP with high accuracy and high efficiency is required. In addition, machining stack materials composed of CFRP and titanium alloys is required. Therefore, in this study, a novel end-mill electroplated with a cubic boron nitride (cBN) abrasive, which has high thermal resistance, is proposed. In order to evaluate the influence of the base metal shape of the proposed end-mill on the machining process, several cBN-electroplated end-mills with different rake angles or chamfers were fabricated and used to cut CFRP. In addition, in order to evaluate the abrasive shape, a blocky abrasive was also electroplated on the end-mill. The results indicate that the negative rake angle is useful to restrain the progression of tool wear. However, in order to obtain the element of cutting and grinding, it is required that the rake angle should be positive. Moreover, the reasonable width of chamfer is effective for restraining the increase in CFRP temperature. Further, a sharp shaped abrasive can more effectively generate a CFRP with a sharp edge compared with a blocky shape abrasive.

A New and Accurate Mathematical Model for Computer Numerically Controlled Programming of 4Y1 Wheels in 2½-Axis Flute Grinding of Cylindrical End-Mills

2013 ◽  
Vol 135 (4) ◽  
Author(s):  
Silai Xiao ◽  
Liming Wang ◽  
Zezhong C. Chen ◽  
Shequan Wang ◽  
Aiming Tan
Keyword(s):  
Mathematical Model ◽  
Research Result ◽  
Rake Angle ◽  
Diamond Wheel ◽  
End Mill ◽  
Helical Angle ◽  
Computer Numerically Controlled ◽  
Solid Carbide ◽  
End Mills ◽  
Set Up

Solid carbide cylindrical end-mills are widely used in machining, and their helical flutes are crucial to their cutting performance. In industry, the flute is simply defined with four key parameters: the helical angle, the radial rake angle, the fluting angle, and the core radius, which are specified in an end-mill design. The flute shape is not fully defined, while it is often generated by a 1A1 or 1V1 diamond wheel in 2½-axis computer numerically controlled (CNC) grinding. Unfortunately, the two simple wheels cannot make largely different flute shapes, preventing further improvement of the end-mills. Although no research result on how the flute geometry affects the end-mill cutting attribute has come into public yet, it is now necessary to employ more complicated wheels to grind flutes with the specified parameter values but much different flute shapes. For this purpose, the 4Y1 diamond wheel is employed in this work. However, the commercial tool grinding software cannot determine the dimensions and the set-up angle for the 4Y1 wheel. To address this problem, a new mathematical model of the flute parameters in terms of the dimensions and the set-up angle of the 4Y1 wheel is formulated, thus, the 4Y1 wheel can be used in flute grinding. This work lays a foundation of using complex wheels to grind flutes with more shapes in order to improve the end-mill's cutting ability.

Fabrication of Electroplated CBN End-Mill for High-Efficiency Face Milling of Carbon Fiber Reinforced Plastic

2015 ◽  
Author(s):  
Tatsuya Furuki ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama ◽  
Keiji Ogawa ◽  
Kiyofumi Inaba
Keyword(s):  
Carbon Fiber ◽  
Carbon Fiber Reinforced Plastic ◽  
Fiber Reinforced ◽  
End Mill ◽  
Fiber Reinforced Plastic ◽  
Coated Tools ◽  
Reinforced Plastic ◽  
End Mills ◽  
Carbon Fiber Reinforced ◽  
The Cost

Carbon fiber reinforced plastic (CFRP) was developed in the 1960s. Since then, it has been used in various fields. Accordingly, the number of studies related to machining of CFRP has been increasing (e.g. cutting, laser processing, or abrasive water jet machining). However, these studies have been focusing on the trimming of surplus portions or drilling. In addition, the degradation of mechanical properties due to the heat induced during machining has not been sufficiently considered. Furthermore, another issue is the cost involved, such as tool and equipment costs. This makes several of these proposed methods tremendously expensive. Therefore, in this study, electroplated end-mills with electrodeposited cBN or diamond grains of different grit sizes (the mesh size are #600, #1000, #1500 and #2000) are fabricated. As a result, the cost of the electroplated tool will decrease by 2/3 compared to general diamond-coated tools. Moreover, the flat cutting of CFRP is often carried out with these fabricated tools and with general diamond-coated tools. In cases where the fabricated tools are used, the machined CFRP products are burr-free or nap-free. Additionally, the induced CFRP temperature during cutting decreases compared to the case of diamond-coated tools. From these results, the optimum grit size was determined to be #1000. On the other hand, end-mills with deposited cBN or diamond grains, fixed on the tip of the fabricated tool, occasionally dropped out after a few paths. Therefore, efforts are presented to improve the tool tip shape and minimize its grain dropout rate. Based on such improved characteristics, the electrodeposited end-mill is expected to be able to machine CFRP more effectively.

scholarly journals Cutting Performance of Different Coated Micro End Mills in Machining of Ti-6Al-4V

Micromachines ◽  
2018 ◽  
Vol 9 (11) ◽  
pp. 568 ◽  
Author(s):  
Zhiqiang Liang ◽  
Peng Gao ◽  
Xibin Wang ◽  
Shidi Li ◽  
Tianfeng Zhou ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Edge ◽  
Micro Milling ◽  
End Mill ◽  
Coating Materials ◽  
Edge Chipping ◽  
Workpiece Surface ◽  
Micro End Mill ◽  
End Mills ◽  
Flank Surface

Tool wear is a significant issue for the application of micro end mills. This can be significantly improved by coating materials on tool surfaces. This paper investigates the effects of different coating materials on tool wear in the micro milling of Ti-6Al-4V. A series of cutting experiments were conducted. The tool wear and workpiece surface morphology were investigated by analyzing the wear of the end flank surface and the total cutting edge. It was found that, without coating, serious tool wear and breakage occurred easily during milling. However, AlTiN-based and AlCrN-based coatings could highly reduce cutting edge chipping and flank wear. Specifically, The AlCrN-based coated mill presented less fracture resistance. For TiN coated micro end mill, only slight cutting edge chipping occurred. Compared with other types of tools, the AlTiN-based coated micro end mill could maximize tool life, bringing about an integrated cutting edges with the smallest surface roughness. In short, the AlTiN-based coating material is recommended for the micro end mill in the machining of Ti-6Al-4V.

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