A novel CNC grinding method for the rake face of a taper ball-end mill with a CBN spherical grinding wheel

Chen, Fang; Bin, Hongzan

doi:10.1007/s00170-008-1554-x

Cited by 36 publications

(18 citation statements)

References 14 publications

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“…3, the representation of w is = 1 X s (11) Since the normal rake angle ocp is the angle between r and i, the line vector r can be easily represented in the coordinate system (12) According to the relationship between the two coordinate systems, »'' and SR"^, the mapping matrix M*""^*' from K"" to K' is rs rw Finally, the unit normal vector n of the rake face can be expressed as…”

Section: Parametric Representation Of the Side Cuttingmentioning

confidence: 99%

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

Rababah

Chen

2013

Journal of Manufacturing Science and Engineering

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In solid carbide end-mills, the flutes signiflcantly 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 specifled 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 (WOLj in 5-axis grinding of the cylindrical end-milt flutes. In this work, a new concept of5-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 manufacttmng (CAD/CAE/CAM) of endmills.

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Section: Parametric Representation Of the Side Cuttingmentioning

confidence: 99%

“…Besides, the profiles of the grinding-wheels are not presented with explicit equations. To address the problems, Chen and Bin [11] and Feng and Bin [12] proposed an approach. In the approach, the rake face is cut on a multi-axis grinding machine tool with standard grinding-wheels.…”

Section: Introductionmentioning

confidence: 99%

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

Rababah

Chen

2013

Journal of Manufacturing Science and Engineering

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“…The research on ball-end mill cutters manufacturing has drawn the interest of many researchers. Several related works on the aforementioned topics are concerned with the design and machining of the helical groove, cutting edge curves or take insights on some special cases in the design and manufacture [1][2][3][4][5][6][7]. The results and conclusions in some specific cases can hardly be applied to others in practice.…”

Section: Introductionmentioning

confidence: 99%

A practical approach for simulation and manufacturing of a ball-end mill using a 5-axis CNC grinding machine

Pham

2010

J Mech Sci Technol

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This paper presents a detailed manufacturing model that can be used for grinding a ball-end mill using 5-axis CNC (computer numerical controlled) grinding machine. The profile of the helical groove can be calculated exactly using the given wheel profile and relative movements between the workpiece and the grinding wheel. The proposed model is related to some analytical, differential geometry and kinematics to control the motions of the workpiece and grinding wheels in grinding processes. The manufacturing model presented in this paper provides a practical and efficient method for developing the simulation software for the design and the manufacture of a ball-end mill.

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“…This method is time-consuming and less accurate. Chen and Bin [18] rendered a five-axis CNC programming method for grinding the rake face of a tapered end-mill. Rababah and Chen [19,20] developed an optimization model of five-axis flute grinding to determine the dimensions of a regular wheel and its location and orientation to minimize the flute machining error.…”

Section: Introductionmentioning

confidence: 99%

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

Silai

Wang²,

Chen

et al. 2013

Journal of Manufacturing Science and Engineering

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Solid carbide cylindrical end-mills are widely used in machining, and their helical flutes are crucial to their cutting peiformance. 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 ofien generated by a lAl or IV1 diamond wheel in 2^l2-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 4YI 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 setup 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.

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A novel CNC grinding method for the rake face of a taper ball-end mill with a CBN spherical grinding wheel

Cited by 36 publications

References 14 publications

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

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

A practical approach for simulation and manufacturing of a ball-end mill using a 5-axis CNC grinding machine

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

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