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Research Papers

A Generalized and Efficient Approach for Accurate Five-Axis Flute Grinding of Cylindrical End-Mills

[+] Author and Article Information
Lei Ren

The State Key Laboratory
of Mechanical Transmission,
Chongqing University,
No. 174 Shazhengjie, Shapingba District,
Chongqing 400044, China
e-mail: renlei@cqu.edu.cn

Shilong Wang

Mem. ASME
The State Key Laboratory
of Mechanical Transmission,
Chongqing University,
No. 174 Shazhengjie, Shapingba District,
Chongqing 400044, China
e-mail: slwang@cqu.edu.cn

Lili Yi

The State Key Laboratory
of Mechanical Transmission,
Chongqing University,
No. 174 Shazhengjie, Shapingba District,
Chongqing 400044, China
e-mail: easypower@126.com

1Corresponding author.

Manuscript received October 24, 2016; final manuscript received June 17, 2017; published online November 3, 2017. Assoc. Editor: Radu Pavel.

J. Manuf. Sci. Eng 140(1), 011001 (Nov 03, 2017) (15 pages) Paper No: MANU-16-1560; doi: 10.1115/1.4037420 History: Received October 24, 2016; Revised June 17, 2017

Wheel position (including wheel location and orientation) in the flute grinding process of an end-mill determines the ground flute's geometric parameters, i.e., rake angle, core radius, and flute width. Current technologies for calculating the wheel position to guarantee the three parameters' accuracy are either time-consuming or only applicable to the grinding wheels with singular points. In order to cope with this problem, this paper presents a generalized and efficient approach for determining the wheel position accurately in five-axis flute grinding of cylindrical end-mills. A new analytic expression of the wheel location is derived and an original algorithm is developed to search for the required wheel position. This approach can apply not only to the wheels with fillets but also to the wheels with singular points. Simulation examples are provided to validate the new approach and compared with the results from other literature. Besides the ability to determine the wheel position, the new approach can evaluate extrema of the core radius and flute width that a specified wheel can generate. Owing to the evaluated extrema, automatic 1V1 wheel customization according to the designed flute is realized in this paper. This work can improve the efficiency and automation degree of the flute grinding process and lay a good foundation for the development of a comprehensive computer-aided design and computer-aided manufacturing system for end-mill manufacturing.

Copyright © 2018 by ASME
Topics: Grinding , Wheels
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References

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Figures

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Fig. 1

Four types of wheels for flute grinding: (a) double-conical wheel, (b) 1V1 wheel, (c) 1A1 wheel, and (d) 1F1 wheel

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Fig. 2

Definition of the general wheel model

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Fig. 3

Definition of the flute parameters

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Fig. 4

Relative position between the wheel and workpiece at the specific moment in the flute grinding process

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Fig. 5

Two types of abnormal flutes: (a) the flute with a negative core radius and (b) the flute with a flute width over 180 deg

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Fig. 6

Wheel projection on the x–y plane when the generated flute has a negative core radius

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Fig. 7

Flowchart of the simulation programming

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Fig. 8

Effects of the setting parameters on the generated core radius and flute width: (a) the surface of the core radius with respect to (hc,λ), (b) the effect of λ on the generated core radius for a certain hc, and (c) the effect of hc on the generated flute width with the designed core radius being guaranteed

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Fig. 9

Procedure for determining the global maximum of the core radius

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Fig. 10

Procedure for determining the local maximum of the core radius

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Fig. 11

Procedure for determining the flute width corresponding to the designed core radius

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Fig. 12

Procedure for determining the setting parameters guaranteeing the designed core radius and flute width

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Fig. 13

Flute profiles obtained by inputting the determined wheel positions into the simulation programming

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Fig. 14

Surface of the core radius when Rw=5mm, δ=35 deg, and γ′=10 deg

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Fig. 15

Relationships between the maximum core radius and wheel parameters: (a) the maximum core radius increases as the fillet radius r1 decreases, (b) the maximum core radius remains unchanged as the inclined angle β1 varies, and (c) the maximum core radius remains unchanged as the wheel radius R0 varies

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