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.

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.

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.

Parameter Optimization of a Five-Axis Tool Grinder Using Grey Relational Analysis

2010 ◽  
Vol 458 ◽  
pp. 246-251 ◽  
Author(s):  
Jenn Yih Chen ◽  
Bean Yin Lee
Keyword(s):  
Grey Relational Analysis ◽  
End Mill ◽  
Relational Analysis ◽  
Control Factors ◽  
Planning And Design ◽  
End Mills ◽  
Optimal Values ◽  
Inspection Machine ◽  
Grey Relational ◽  
Five Axis

This paper uses the grey relational analysis to find the optimal values of parameters of the servo drives and the controller of a five-axis CNC tool grinder in order to improve precision of grinding and accuracy of end mills. The experimental planning and design are based on the Taguchi method. There are totally six control factors in the experiments, and each factor has three levels. An L18 orthogonal array was applied for the experiments, and each experiment was repeated three times. The grey relational approach was then employed to find the optimal values to the drives and the controller. These values were utilized for grinding a ball nose end mill of cemented tungsten carbide with two-flute and 6 mm in outside diameter. Finally, a well-known tool measuring and inspection machine was used to measure the geometric parameters of the end mill for the initial design and the optimal design. Experimental results show that the grinding time is reduced up to 6.02 ％, and the precision of the ball nose end mill is also improved. Thus, the results demonstrate the effectiveness of the proposed approach.

Using the Flat-End Mill in the Strip Width Machining

2012 ◽  
Vol 723 ◽  
pp. 170-173
Author(s):  
Can Zhao ◽  
Yun Fei Guan ◽  
Yan Yan Guo
Keyword(s):  
Difficult Problem ◽  
Strip Width ◽  
End Mill ◽  
Machining Time ◽  
Surface Machining ◽  
Large Program ◽  
End Mills ◽  
Tool Position ◽  
Five Axis ◽  
Processing Cycle

Surface machining has become a difficult problem in aviation manufacturing, we always using ball-end mills, it is easy to determine the tool position in five-axis machining, but because of the large program, low material remove rate, the processing cycle long, and the surface accuracy is also poor. The paper suggests using the flat-end mill to strip width machining. Using this way, the CNC program is shorter, surface quality is better, the most import is reducing the machining time obviously. Now this method only used in the simple surface, so it requires further research.

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.

Design of a CAM System for End Mills Based on Solid Modeling

2011 ◽  
Vol 201-203 ◽  
pp. 841-845
Author(s):  
Zhan Hua You ◽  
Fei Tang ◽  
Shu Zhe Li ◽  
Xiao Feng Yue ◽  
Xiao Hao Wang
Keyword(s):  
Solid Modeling ◽  
Numerical Control ◽  
Design Parameters ◽  
End Mill ◽  
Nc Code ◽  
Inner Radius ◽  
End Mills ◽  
Grinding Machine ◽  
Five Axis ◽  
Mill Machining

To facilitate the manufacturing of an end mill, this paper presents a manufacturing model of a flat-end mill using a five-axis computer numerical control (CNC) grinding machine. Using input data of end mill geometry, wheels geometry, wheel setting and machine setting, the NC code for machining will be generated directly from a solid modeling then used as input to simulate the end mill machining in 3 Dimension before machining. The 3D simulation system of the end mill grinding is generated by VBA and AutoCAD2008. Machining simulation consists of a sequence of Boolean operations on difference between the tool and the grinding wheels through NC code. Then the major design parameters of a cutter, such as relief angle and inner radius, can be verified by interrogating the section profile of its solid model. The manufacturing model presented in this paper provides a practical and efficient method for developing CAM software for the manufacture of an end mill.

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.

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

2012 ◽  
Vol 723 ◽  
pp. 421-432 ◽  
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.

Optimization of simplified grinding wheel geometry for the accurate generation of end-mill cutters using the five-axis CNC grinding process

2019 ◽  
Vol 105 (10) ◽  
pp. 4325-4344 ◽  
Author(s):  
Muhammad Wasif ◽  
Syed Amir Iqbal ◽  
Aqeel Ahmed ◽  
Muhammad Tufail ◽  
Mahmoud Rababah
Keyword(s):  
Grinding Wheel ◽  
Grinding Process ◽  
End Mill ◽  
Cnc Grinding ◽  
Five Axis
Sign in / Sign up

Export Citation Format

Share Document