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research-article

A generalized and efficient approach to 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
renlei@cqu.edu.cn

Shilong Wang

The State Key Laboratory of Mechanical Transmission, Chongqing University, No.174 Shazhengjie, Shapingba District, Chongqing, 400044, China
slwang@cqu.edu.cn

Lili Yi

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

1Corresponding author.

ASME doi:10.1115/1.4037420 History: Received October 24, 2016; Revised June 17, 2017

Abstract

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 grinding wheels with singular points. In order to cope with this problem, this paper presents a generalized and efficient approach to 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 wheels with fillets but also to wheels with singular points. Simulation examples are provided to validate the new approach and compared with the results from other literatures. Besides the ability to determine wheel position, the new approach can evaluate the extrema of core radius and flute width that a specified wheel can generate. Owing to the evaluated extrema, automatic 1V1 wheel customization according to a designed flute is realized in this paper. This work can improve the efficiency and automation degree of flute grinding process and lay a good foundation for the development of a comprehensive computer-aided design and computer-aided manufacturing (CAD/CAM) system for end-mill manufacturing.

Copyright (c) 2017 by ASME
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