Optimising the grinding wheel design for flute grinding processes utilising numerical analysis of the complex contact conditions

Abstract

Resource efficiency is gaining relevance in every aspect of production. Hence, cutting tools are exposed to high demands regarding productivity and quality. Considering the various grinding operations in tool manufacturing, flute grinding is the most significant process step as it defines the peripheral cutting edge and the rake face. Therefore, it has a substantial influence on the machining behaviour of, for example, milling tools. When it comes to helical flutes, the complex contact conditions between grinding wheel and tool blank during the multiaxial grinding process are particularly difficult to determine. Due to the lack of knowledge about those contact conditions, the grinding wheels typically used for flute grinding cannot wholly meet the actual process requirements. In order to optimise the design of the grinding wheels, a numerical model was developed. Based on that, a simulation tool was implemented to analyse the complex contact conditions during flute grinding depending on the process parameters and tool/workpiece geometry. The influence of different grinding parameters on the effective contact length, the specific material removal rate and the equivalent chip thickness was evaluated by employing the computer-based model. The generated results were then used to develop a new optimised tool concept for a more efficient flute grinding process.

Application of Mathematical Morphology in Solving the Profile of Forming Grinding Wheel

“…According to the condition that the contact point lies on both the rotating surface and spiral surface of the grinding wheel, the contact point is rotated around the axis of the grinding wheel, and the grinding wheel contour equation is obtained after ftting. Uhlman et al [3] optimized the grinding wheel design for fute grinding processes by using the numerical analysis of complex contact conditions. Wasif et al [4] used a fve-axis NC grinding process combined with contact conditions to generate a simplifed grinding wheel geometry for grinding end mills.…”