An iterative optimization algorithm for posture and geometric parameters of grinding wheel based on cross-section sensitivity and matching constraints of solid end mills

Li, Yong; Ding, Guofu; Xia, Changjiu; Ning, Yangcheng; Jiang, Lei

doi:10.1016/j.jmapro.2022.05.011

Cited by 11 publications

(5 citation statements)

References 23 publications

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“…The constraint 0 < λ < π / 2 -β(u1,i) is the conservative range of the wheel orientation that avoids overcutting occurring in the rake face [5], and the constraint |ξ| ≤ 1 comes from Eq. (20). By using the penalty method, the problem is reformulated as…”

Section: Optimization Model Of Wheel Path Planningmentioning

confidence: 99%

“…With regard to the flute grinding of a cylindrical end-mill with variable geometric parameters, Li et al [19] simplified the flute geometry as four characteristic curves and derived the wheel position by making the wheel surface be tangent to the four curves to generate the variable core radius and pitch; Based on cross-section sensitivity analysis, Li et al [20] proposed the iterative algorithm for searching the wheel position to generate the variable core radius, and they presented the two-pass grinding method for the flute with segmented unequal helical angles [21]. With respect to the flute grinding of tapered end-mills, some researchers [22,23] derived the wheel location by the conjugate condition between the wheel surface and the cutting-edge curve and minimized the machining error of the variable core radius iteratively; Wang et al [24] discretized the tapered end-mill into a series of thin cylindrical end-mills and then the problem of wheel path planning is converted to a series of sub-problem of wheel position determination for cylindrical end-mills; Roy et al [25] applied deep learning method to generate the wheel path that can yield the desired variable core radius and flute width, of which the input parameters contains the flute parameters and wheel geometry and the output parameters are the wheel positions and the minimum wheel width.…”

Section: Introductionmentioning

confidence: 99%

“…Up to now, the problem of wheel path planning in flute grinding of non-cylindrical end-mills still deserves further investigation. The methods presented in the public literature have some limitations such as the inability to control the variable flute width [15-18, 20-22, 23], low efficiency due to the need for cross-section prediction [20][21][22]24], applicability only to wheels with sharp edges [19], and excessive complexity [24,25]. To overcome these limitations, this paper proposes a new method of wheel path planning for flute grinding of non-cylindrical end-mills based on circular arc projection (CAP).…”

Section: Introductionmentioning

confidence: 99%

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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: Optimization Model Of Wheel Path Planningmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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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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show abstract

“…e prediction model was developed from ANOVA results of response surface methodology [17]. Based on the cross section sensitivity and matching restrictions of solid end mills, an iterative optimization approach was developed for the bearing and geometric parameters of grinding wheels [18]. is research interest is unique.…”

Section: Research Gapmentioning

confidence: 99%

High Speed Grinding of EN31 Steel with Alumina Nanofluid Coolant

Sathish

Saravanan

Rajkumar³

et al. 2022

Advances in Materials Science and Engineering

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Grinding is a choice for obtaining high surface quality and closer dimensional tolerance. For meeting this objective economically, the material removal rate (MRR) must be sacrificed to certain extent. The MRR could be increased by either increase in wheel speed, depth of cut, and feed rate. An increase in MRR increases the surface temperature leading to thermal defects on surfaces. Improving the MRR without compromising the surface quality is a challenging objective. Many investigations are progressing for machining various materials under different cooling environments to meet such challenges. This experimental novel aim is to investigate the performance of Al2O3 nanofluid in high-speed grinding of EN31 steel under flood cooling method for reduction of surface roughness and cutting zone temperature. Taguchi’s full factorial design was employed for experimental investigation. The factors such as feed, depth of cut and cutting fluid environment were considered for analysing the responses of cutting zone temperature and surface roughness. The thermal analysis on the work piece was carried out with experimental values by the finite element analysis method. The nanofluids outperform in terms of reduction of surface roughness and downsizing cutting zone temperature. The proposed nanofluid-based grinding significantly reduced the surface roughness and cutting zone temperature.

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“…Jia et al [9] developed a grinding wheel orientation calculation method that combines the specific process for helical rake flank sharpening with discrete enveloping theory. Li et al [10] analyzed the influence of the parameters and posture of the grinding wheel on the parameters of the helical flute, and an algorithm to iterate the posture and geometric parameters of the grinding wheel for the helical flute with variable core radius was proposed.…”

Section: Introductionmentioning

confidence: 99%

An optimized calculation method of the grinding wheel profile for the helical flute grinding

Jiang¹,

Yang²,

Li³

et al. 2023

Preprint

Self Cite

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Forming grinding process is a crucial method for grinding the helical flute of end mills, and the calculation of the grinding wheel profile is the key to ensure the precision of the helical flute, which is constrained by grinding wheel posture and helical flute profile. However, the current calculation method has not done enough research on the estimation of the feasibility and validity of the grinding wheel profile, which could lead to contradiction between theoretical calculations and practical application. In this paper, an optimized calculation method of the grinding wheel profile for the helical flute forming grinding is proposed, which includes the calculation, analysis and optimization process. Firstly, the parameters of the helical cutting edge and the flute surface are defined, and accurate geometrical models are established. Secondly, the contact condition between the grinding wheel and the flute surface is deduced to calculate the grinding wheel profile by the envelop theory. Thirdly, an optimization method, including profile optimization and grinding wheel wear optimization, is proposed for the calculation of the grinding wheel profile. Finally, the method is verified by simulation machining and the results show that the method can improve the grinding precision and expand the application range of forming grinding technology in helical flute grinding.

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An iterative optimization algorithm for posture and geometric parameters of grinding wheel based on cross-section sensitivity and matching constraints of solid end mills

Cited by 11 publications

References 23 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

High Speed Grinding of EN31 Steel with Alumina Nanofluid Coolant

An optimized calculation method of the grinding wheel profile for the helical flute grinding

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