Research Papers

A New Method for Determination of Wheel Location in Machining Helical Flute of End Mill

[+] Author and Article Information
Van-Hien Nguyen

Department of Mechanical Design
and Production Engineering,
Konkuk University,
120 Neungdong-ro,
Gwangjin-gu, Seoul 143-701, South Korea
e-mail: nguyenvanhiencdt49@gmail.com

Sung-Lim Ko

Department of Mechanical Design
and Production Engineering,
Konkuk University,
120 Neungdong-ro,
Gwangjin-gu, Seoul 143-701, South Korea
e-mail: slko@konkuk.ac.kr

Manuscript received June 9, 2015; final manuscript received March 23, 2016; published online June 23, 2016. Assoc. Editor: Guillaume Fromentin.

J. Manuf. Sci. Eng 138(11), 111003 (Jun 23, 2016) (11 pages) Paper No: MANU-15-1282; doi: 10.1115/1.4033232 History: Received June 09, 2015; Revised March 23, 2016

This paper presents a mathematical model to find the wheel location in grinding a given helical flute of an end mill. Two new setting parameters are introduced to define the relative wheel location in workpiece coordinates. This model allows the wheel-axis orientation be expressed explicitly as a function of the design factors and machine setting parameters. By utilizing this explicit form of the wheel orientation and analyzing the influence of setting parameters on design parameters, a new efficient search algorithm is proposed, and the performance shows that the required wheel location is found within 1.5 s to machine a given flute profile. Moreover, the rake angle can be produced more precisely compared with the conventional methods, which have been used with approximations. A comprehensive development of the software for designing and grinding the helical flute of the end mill is presented, which provides a technology and good foundation for the development of a computer-aided design and computer-aided manufacturing (CAD/CAM) system for manufacturing end mills. The results of the experiment, simulation, and design are compared in order to verify of the proposed method.

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Fig. 1

Conventional model and suggested model for helical flute machining

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Fig. 2

(a) General grinding wheel profile, (b) geometrical design of the flute profile, and (c) elementary components of the cutting edge

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Fig. 3

Geometrical relationship between the wheel orientation and the elementary components of the flute

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Fig. 4

Spaced curve of the contact line between the wheel surface and the machined flute

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Fig. 5

Notation for the calculation of the contact line

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Fig. 6

Generated helical flute with the designed rake angle corresponding to the change of pairs (α, λ): (a) standard wheel for the fabrication of an end mill, (b) generated flute for example 1, (c) flute profile for example 1, and (d) flute profile for example 2

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Fig. 7

Influence of the setting parameters on the design parameters. (a) Influence of α on the core radius, (b) influence of λ on the core radius, (c) influence of α on the flute angle, (d) influence of λ on the flute angle, and (e) influence of λ on the flute angle with a constant core radius.

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Fig. 8

Proposed binary search algorithms: (a) main procedure to determine (α, λ) satisfying the design factors and (b) subprocedure to determine α satisfying the core radius for a given λM

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Fig. 9

General structure of the software

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Fig. 12

Results for sample 1: (a) flute profile of experiment sample, (b) flute profile of simulation sample, (c) verification of profile curve by cutting simulation, (d) 3D configuration of the generated flute, (e) overlapping profile curve of the experimental and simulated results, and (f) contact line between the wheel surface and the machined flute

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Fig. 13

Results for sample 2: (a) flute profile of the experimental sample, (b) flute profile of the simulation sample, (c) verification of the profile curve by the cutting simulation, and (d) 3D configuration of the generated flute

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Fig. 14

Illustration of computation of the core radius




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