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.

Study on Establishment of Helix Flute Mathematic Model of Solid Carbide End Mills

2011 ◽  
Vol 121-126 ◽  
pp. 4753-4757
Author(s):  
Guo Chao Li ◽  
Jie Sun ◽  
Yong He
Keyword(s):  
Mathematical Model ◽  
Main Idea ◽  
Surface Group ◽  
Mathematic Model ◽  
End Mill ◽  
Cross Sectional ◽  
New Approach ◽  
Solid Carbide ◽  
End Mills ◽  
The Mathematical Model

This paper describes a new approach to establish the helix flute model of solid carbide end mills. Based on the theory of differential geometry and coordinate transformation, a mathematical model of the end mill helix flute will be established.The main idea of the study is to envelop the helix flute by a one-parameter surface group which consists of the cross-sectional profiles of the wheel.Then, the mathematical model will be quickly verified by MATLAB.Thus the end mill design time will be saved and the new mathematical model will be checked effectively.

Research of Riveting Structure Identification and Characteristic Parameter Analysis Based on SVM

2014 ◽  
Vol 1049-1050 ◽  
pp. 1554-1557
Author(s):  
Jian Feng Yang ◽  
Gang Jiang ◽  
Jian Fei Chen
Keyword(s):  
Mathematical Model ◽  
Image Processing ◽  
Research Result ◽  
Characteristic Parameter ◽  
Parameter Analysis ◽  
Structure Identification ◽  
Support Vector ◽  
Vector Machines ◽  
Set Up ◽  
The Mathematical Model

In order to help department to make a decision whether the equipment need maintenance, some people trained the sample of characteristic parameter for riveting structure, and set up the model to recognize target by computer vision. However, we are difficult to find the research result about the affiliation between the characteristic parameter of the riveting structure and the model. In this paper, we make the image processing first, and use SVM (Support Vector Machines) algorithm to train the sample of characteristic parameter for rivet head. Finally, we research the affiliation between the characteristic parameter for the rivet head and the mathematical model, and test the accuracy of the model.

Research on Dynamic Temperature Field Modeling of the Solid Carbide End Mill in High-Speed Milling

2015 ◽  
Vol 1089 ◽  
pp. 350-353
Author(s):  
Wei Bo ◽  
Guang Yu Tan ◽  
Lin Lin Guo ◽  
Guang Hui Li
Keyword(s):  
Temperature Field ◽  
Heat Source ◽  
High Speed ◽  
Cutting Temperature ◽  
Helical Coil ◽  
End Mill ◽  
Dynamic Temperature ◽  
Solid Carbide ◽  
End Mills ◽  
Coil Heat

Cutting temperature is a key factor in impacting the solid carbide end mill’s life, the rule of solid carbide end mill temperature field is the research focus. In this paper, the solid carbide end mill helical side edge is regarded as a helical coil heat source, the tool chip friction surface is considered as a surface heat source which consists of countless helical coil heat source. Based on heat source method, the model of continuous dynamic temperature field simulation of a solid carbide end mills cutting process is established.

Research on the Mathematical Model of Helical Groove of the End Mill Based on the Grinding Wheel Attitude

2013 ◽  
Vol 589-590 ◽  
pp. 416-420 ◽  
Author(s):  
Xian Feng Zhao ◽  
Lin He ◽  
Hong Yan Shi
Keyword(s):  
Mathematical Model ◽  
Differential Geometry ◽  
Relative Motion ◽  
3D Model ◽  
Rake Angle ◽  
Grinding Wheel ◽  
End Mill ◽  
Helical Groove ◽  
The Mathematical Model ◽  
Main Factor

This paper presents the mathematical model of helical groove of the end mill according to the differential geometry and meshing principle based on the grinding wheel attitude. The profile of the helical groove can be precisely calculated using a given wheel attitude and the relative motion between the workpiece and the grinding wheel.The relation between the grinding wheel attitude and the rake angle can be obtained through adjusting the grinding wheel attitude angle.And the accurate 3D model of helical groove was generated in the SolidWorks.The research shows that the grinding wheel attitude is the main factor that affects the rake angle of end mill.There is a linear relationship between the rake angle and the grinding wheel attitude. The smooth and accurate 3D model of helical groove lay the foundation for studying the cutting performance and dynamic characteristics of end mill.

scholarly journals ANALYZING THE PERFORMANCE OF CIRCLE SEGMENT END MILL WITH PCD INSERTS WITH LASER-MACHINED INTEGRAL CHIPBREAKER WHEN DRY MILLING OF ADDITIVE MANUFACTURED TI-6AL-4V TITANIUM ALLOY

2021 ◽  
Vol 2021 (2) ◽  
pp. 4434-4443
Author(s):  
TOMAS TRCKA ◽  
◽  
ALES POLZER ◽  
Keyword(s):  
Dimensional Accuracy ◽  
Tool Geometry ◽  
End Mill ◽  
Dry Cutting ◽  
Workpiece Material ◽  
Machined Surface ◽  
Cutting Geometry ◽  
Solid Carbide ◽  
End Mills ◽  
Complex Parts

Components with generally shaped surfaces requiring higher surface quality and dimensional accuracy are, in most cases, machined. Specifically, milling technology is involved very often, which can be supplemented by finishing operations. Besides standard ball-nose end mills, circle segment end mills are modern type of cutter that has begun to be used with the development of advanced computer aided machining software, that allows to work with these shaped tools. In this research, comparing the performance of these two modern shaped end mills was investigated. One tool was a commercially available coated solid carbide circle segment end mill. A second prototype end mill with the same profile but different geometry was made with a PCD insert, that additionally had a chipbreaker produced by laser technology. Machining was carried out on the workpiece material the Ti-6Al-4V that was manufactured by additive manufacturing (AM) technology – selective laser melting (SLM). The titanium complex parts are generally used in the transport industries and medicine. Milling tests were performed under dry cutting conditions. The evaluation was based on the force load, the roughness of the machined surface and tool wear. The higher total forces were measured by the tool with a PCD insert, because a different tool geometry was used, despite the use of integral chipbreaker, which allows a partial change of the cutting geometry of the insert. The geometry of end mills with brazed insert is limited by the production process.

Optimization of Cutter Geometry Features to Minimise Cutting Force on Machining Polyetheretherketone (PEEK) Engineering Plastic

2015 ◽  
Vol 761 ◽  
pp. 282-286 ◽  
Author(s):  
Raja Izamshah ◽  
Nurul Husna ◽  
Mohd Hadzley ◽  
Mohd Amran ◽  
Mohd Shahir Kasim ◽  
...  
Keyword(s):  
Cutting Force ◽  
Helix Angle ◽  
Rake Angle ◽  
Tool Geometry ◽  
Thermoplastic Material ◽  
Solid Carbide ◽  
End Mills ◽  
Geometry Feature ◽  
High Thermal Expansion ◽  
Optimal Values

Machining of thermoplastic material poses several challenges due to its low melting temperature and high thermal expansion which directly related to cutting force. Thus, controlling the cutting force and temperature is desirable for machining polyetheretherketone (PEEK). The cutting force is dependent on friction and shearing action produced by the tool. It is indicated the cutting force is significantly affected by tool cutter geometry. This paper aims to control the cutting force by optimizing the cutter geometries especially rake, clearance and helix angle on machining PEEK. The two –flutes of solid carbide ball nose end mills were used to conduct the experiments and the cutting force acquired was measured using piezoelectric dynamometer. Response Surface Methodology (RSM) approach was applied to design and analyse the optimal combination of tool geometry feature for machining PEEK. Based on obtained results, the best optimal values of tool geometry which contribute to minimum of cutting force were 17° rake angle, 26° of helix angle and 10° of clearance angle. The best control of tool geometry ultimately improves the cutting performance and reduces defect caused by high cutting forces.

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.

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.

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.

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.

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