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

Rababah, Mahmoud; Chen, Zezhong C.

doi:10.1115/1.4023271

Cited by 28 publications

(9 citation statements)

References 10 publications

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“…Hence, the wheel path can be generated if the wheel position at any given moment during the flute grinding process is determined. Based on the conjugate condition between the wheel surface and the cutting edge curve, Rababah and Chen [2] derived the analytical expression of wheel position that can generate the rake angle accurately, and they minimized the error of core radius by a one-dimensional search method. Based on the same principle, methods for searching the optimal wheel position that can minimize the errors of core radius and flute width simultaneously were proposed for the wheel with singular points [3] and for the wheel with fillets [4].…”

Section: Introductionmentioning

confidence: 99%

Wheel path planning for flute grinding of non-cylindrical solid end-mills based on circular arc projection

Ren,

Zhang,

et al. 2024

Preprint

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Flute grinding is a crucial process in solid end-mill manufacturing, because the generated flute parameters, i.e. helix angle, rake angle, core radius, and flute width, have significant effects on the cutting performance of end-mills. However, the flute grinding of non-cylindrical solid end-mills is still challenging due to the variable flute parameters along the tool axis. This paper proposes an accurate and efficient method of wheel path planning for flute grinding of non-cylindrical solid end-mills based on circular arc projection. The wheel path determined by the new method can accurately generate the designed variable helix angle, variable rake angle, variable core radius, and variable flute width. The rake angle is guaranteed by the conjugate condition between the wheel surface and the cutting-edge curve. Equivalent errors of core radius and flute width are introduced in this work based on circular arc projection. The accuracy of the two parameters is ensured by minimizing the sum of squares of the two equivalent errors. Simulations and experiments are conducted to validate the method. Three types of non-cylindrical end-mills i.e. tapered end-mill, tapered barrel end-mill, and barrel end-mill, are considered in the validation. The measured results indicate that the generated flute parameters coincide well with the designed ones at different axial positions of the end-mills.

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Section: Introductionmentioning

confidence: 99%

Wheel path planning for flute grinding of non-cylindrical solid end-mills based on circular arc projection

Ren,

Zhang,

et al. 2024

Preprint

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“…By finding the different influence rates of the wheel position on the machined groove parameters, the wheel position was searched step by step. Based on the directly proportional relationship between the wheel position and the two groove parameters rake angle and core radius, Kim et al [3], Rababah et al [4] and Ren et al [5]roughly searched and slightly adjusted the wheel position by the rake angle and the core radius respectively and successively. Furthermore, the calculation precision was improved by Nguyen et al [6]and Pham et al [7].…”

Section: Introductionmentioning

confidence: 99%

Big data-oriented wheel position and geometry calculation for cutting tool groove manufacturing based on AI algorithms

Liu

Lu³

et al. 2022

Int J Adv Manuf Technol

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Groove is a key structure of high-performance integral cutting tools. It has to be manufactured by 5-axis grinding machine due to its complex spatial geometry and hard materials. The crucial manufacturing parameters (CMP) are grinding wheel positions and geometries. However, it is a challenging problem to solve the CMP for the designed groove. The traditional trial-and-error or analytical methods have defects such as time-consuming, limited-applying and low accuracy. In this study, the problem is translated into a multiple output regression model of groove manufacture (MORGM) based on the big data technology and AI algorithms. The input are 34 groove geometry features and the output are 5 CMP. Firstly, two groove machining big data sets with different range are established, each of which is includes 46656 records. They are used as data resource for MORGM. Secondly, 7 AI algorithms, including linear regression, k nearest-neighbor regression, decision trees, random forest regression, support vector regression and ANN algorithms are discussed to build the model. Then, 28 experiments are carried out to test the big data set and algorithms. Finally, the best MORGM is built by ANN algorithm and the big data set with a larger range. The results show that CMP can be calculated accurately and conveniently by the built MORGM.

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“…Modern technology in the thread milling cutters production is their manufacture using the CNC tool grinding machines (ANCA, WALTER, ROLLOMATIC, etc.) in a single operation with several grinding wheels of various shapes [17][18][19][20][21][22][23]. In the general, the flute surface shape of tools manufactured on the CNC tool grinding machines depends on grinding wheel shape and size, tool parameters and relative position of the tool and of the grinding wheel [24][25][26][27][28][29][30][31].…”

Section: Introductionmentioning

confidence: 99%

Technological preparation of thread milling cutter production at the design stage

Malkov

Pavlyuchenkov

2022

Preprint

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This research was performed on the technological feasibility of manufacturing the multiple thread milling cutter flutes based on their mathematical and experimental simulation and studying possibility of manufacturing a prototype thread milling cutter with use of grinding wheels of typical profiles. System of mathematical expressions was developed to determine the flute end section profile produced by a grinding wheel and taking into account kinematic scheme of the multi-axis CNC tool grinding machines using the Walter Basic kinematic scheme as an example. Proposed mathematical expressions were approved by experimental studies when machining helical flutes on caprolon workpieces with a diameter of 34.5 mm with use of a universal grinding machine. Flute profiles comparison in the end section (experimental and calculated) showed their satisfactory convergence; the errors (up to 0.42 mm) could be explained by inaccuracy in grinding wheel installation, workpiece yielding, error in the experiment parameters settings and increasing discrepancy in the error measurement direction to the core diameter. To study technological feasibility of the thread milling cutter flutes manufacturing, the CoroMill Plura R217.15-140100AC26N thread milling cutter was choosed as a prototype. End section of the tool was obtained by a plane passing through the top of the tooth, and installation parameters for the grinding wheel type 1V1 were assigned using a developed mathematical expressions system. It was established that the grinding wheel type 1V1 made it possible to assign installation parameters required in fluting of the prototype. The possibility of choosing the grinding wheel profile and geometric parameters as well as its installation parameters based on the manufacturing simulation of the prototype performed in Walter Helitronic Tool Studio was confirmed, which makes it possible to perform thread milling cutters production technological preparation using the developed mathematical expressions.

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

Cited by 28 publications

References 10 publications

Wheel path planning for flute grinding of non-cylindrical solid end-mills based on circular arc projection

Wheel path planning for flute grinding of non-cylindrical solid end-mills based on circular arc projection

Big data-oriented wheel position and geometry calculation for cutting tool groove manufacturing based on AI algorithms

Technological preparation of thread milling cutter production at the design stage

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