A new design and grinding algorithm for ball-end milling cutter with tooth offset center

Abstract

Ball-end milling cutter with tooth offset center is widely used in machining industry, because it has higher machining efficiency and better stability compared with the ball-end milling cutter without tooth offset center. In addition, the tooth offset center has lower wear rate of the tool tip so the life of the milling cutter is improved. However, up to present, there is no mature and effective theory for the design and manufacture of this kind of milling cutters. This article presents a new mathematical model for S-shaped edge curve of the ball end taking the tooth offset center into account, which can construct accurate S-shaped edge curve for the ball-end cutting tools with tooth offset center as well as without tooth offset center. This model overcomes the complex computation and bad adaptability of the traditional modeling method. At the same time, a five-axis grinding algorithm for rake face of the ball end is also presented in this article. Finally, based on the application programming interface of CATIA™, a three-dimensional computer-aided design and computer-aided manufacturing system is developed. The accuracy and effectiveness of the grinding algorithm are verified by simulation in VERICUT™ and machining experiment in tool grinding machine.

Research on parametric modeling and grinding methods of bottom edge of toroid-shaped end-milling cutter

“…Although edge b is a planar edge curve, it can be also regarded as a curve with a variable helix angle. At present, the generalized helix angle on the revolving surface has two definitions [24] : one is the angle between the helix edge on the revolving surface and the generator curve [22] , the other is the angle between the helix edge on the revolving surface and the cutter axis [25] . The first definition is considered in this paper.…”

“…Cheng used the orthogonal helix edge curve as the S-shaped edge curve of ball-end milling cutter, the edge curve acquired based on the mathematical model proposed has a good S-shape and can connect with the circumferential edge curve smoothly. Furthermore, the model can be used easily to establish the S-shaped edge curve with tooth offset center or without tooth offset center [22] .…”

“…Furthermore, the model can be used easily to establish the S-shaped edge curve with or without tooth offset center. 25…”

“…Furthermore, the model can be used easily to establish the S-shaped edge curve with or without tooth offset center. 25 Until now, several kinds of curves are used as a bottom edge on TEMC, such as an equal pitch edge curve, an equal helix angle edge curve with the longitude line, an equal helix angle edge curve with the cutter axis, a planar edge curve and an orthogonal helix edge curve. They have good edge curve shapes and can be used in series types of TEMC.…”

Study on design, manufacture, and cutting performance of circular-arc milling cutters for machining titanium alloy

“…In research on the cutting performance and grinding of BEMC, Chen et al [5] presented a new mathematical model for S-shaped edge curve. The model overcomes the complex computation and poor adaptability of the traditional modeling method, and enhances the cutting efficiency and stability of BEMC.…”