A practical method of modelling and simulation for drill fluting

Zhang, Wei; Wang, Xianfeng; He, Feng; Xiong, Dilin

doi:10.1016/j.ijmachtools.2005.07.007

Cited by 38 publications

(13 citation statements)

References 5 publications

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“…Step 5: grinding flank surfaces to generate cutting lips. The drill flute has a high impact to the drill character, such as cutting angles, strength, stability, heat dissipating, chip removing and dynamic behavior (W. Zhang et al, 2006). Especially, it combines with flank surfaces to generate cutting lips, which is crucial part of the drill bit.…”

Section: R a F Tmentioning

confidence: 99%

“…Furthermore, the dynamic analysis of the micro drill makes it to have higher accuracy (A.-C. Lee & Nguyen, 2016). Because the drill flute has a high impact to the drill character, such as D r a f t cutting angles, strength, stability, chip removing and dynamic behavior (W. Zhang, Wang, He, & Xiong, 2006), grinding of the drill flute is an important work of generating the new micro drill. Grinding is a machining process utilizing abrasives for the removal of material.…”

Section: Introductionmentioning

confidence: 99%

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Design of grinding wheel profile for new micro drill flute

Nguyen

Lee

2018

Transactions of the Canadian Society for Mechanical Engineering

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Derived from our previous research, a new micro drill bit with higher accuracy and productivity was developed. Because the drill flute plays a significant role in its cutting performance, the design of grinding wheel profile for the new micro drill flute by an inverse problem method is examined in this research. First, the cross-section of the new micro drill flute is modeled by mathematical equations. Second, machine parameters and workpiece geometric parameters are set up. Third, the engagement equation between the grinding wheel and flute surfaces is developed. Fourth, that equation is solved to obtain the locus of contact points. Finally, the translation and rotation transformations of that locus are carried out to obtain the grinding wheel profile for the new micro drill flute. Numerical examples are demonstrated and validated by Vericut software.

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Section: R a F Tmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Design of grinding wheel profile for new micro drill flute

Nguyen

Lee

2018

Transactions of the Canadian Society for Mechanical Engineering

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“…By means of the indirect method is usually designed the grinding process realized on bi-axial grinders. Designing the process by the indirect method comes to determining the grinding wheel profile applying reverse engineering based on envelope theory [8].…”

Section: Designing Of Tools Outline For Skew Rolling Of Twist Drillsmentioning

confidence: 99%

Numerical Modeling of Skew Rolling Process of Twist Drills

Bulzak

Pater

Tomczak

2016

Adv. Sci. Technol. Res. J.

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This paper presents the results of numerical modeling of skew rolling process of twist drills in four-segments configuration. On the basis of the conducted numerical simulation the results were obtained in a form of distributions: stress intensity, strain intensity, temperature and damage. The energetic parameters of the process were also given on the example of a drill Ø10 mm from high-speed steel HS6-5-2. The conducted numerical simulation confirmed the usefulness of the graphic method based on envelope theory in tools designing for skew rolling of twist drills.

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“…For this case, the contact line method cannot be used to predict the machined flutes. Boolean operation [10][11][12] would be a solution to cope with this problem, but more iteration steps are required to achieve a high accuracy.…”

Section: Introductionmentioning

confidence: 99%

A novel approach to determination of wheel position and orientation for five-axis CNC flute grinding of end mills

Wang

Chen

et al. 2015

Int J Adv Manuf Technol

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In practice, the flutes of end mills are ground using CNC grinding machines via controlling the grinding wheel's position and orientation to guarantee the designed flute parameters including rake angle, flute angle, helix angle, and core radius. However, for the previous researches, the designed flute profile was ground via building a specific grinding wheel with a free-form profile using two-axis CNC grinder. And, the free-form grinding wheel will greatly increase the manufacturing cost, which is too complicated to implement in practice. In this research, the flute-grinding processes were developed with a standard grinding wheel via five-axis CNC grinding operations. The mathematical representation of machined flute parameters was deduced in terms of the grinding wheel's position and orientation. The geometrical constraints to avoid interference and abnormal flute profile for the five-axis CNC fluting were first developed in this work. Finally, the difference between the designed flute parameters and the machined flute parameters were formulated as a constrained optimization problem so as to determine the wheel's position and orientation. The set of effective initial points for this optimization model was found mainly distributed the first quadrant of the contact area. The fminsearch function in Matlab toolbox was recommended to solve the optimization model due to its capability of handling discontinuity problem. The solution obtained in optimization model and the corresponding machined flute parameter were verified and compared with Boolean simulation in CATIA to confirm the validity and efficiency of the proposed approach. The results showed that the accuracy of machined flute parameters could achieve 1e-3 mm and 1e-2°, which satisfied the machining tolerance. This study provides a general solution for the CNC fluting operations and could be extended to grind complex surface of end mills in the future study.

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A practical method of modelling and simulation for drill fluting

Cited by 38 publications

References 5 publications

Design of grinding wheel profile for new micro drill flute

Design of grinding wheel profile for new micro drill flute

Numerical Modeling of Skew Rolling Process of Twist Drills

A novel approach to determination of wheel position and orientation for five-axis CNC flute grinding of end mills

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