Specific material removal rate calculation in 5-axis grinding

[+] Author and Article Information
Raja Kountanya

Member, ASME, Pratt & Whitney, 400 Main St. MS114-42. East Hartford, CT 06118

Dr. Changsheng Guo

Member, ASME, United Technologies Research Center, 411 Silver Lane MS129-22, East Hartford, CT 06108

1Corresponding author.

ASME doi:10.1115/1.4037969 History: Received March 30, 2017; Revised September 19, 2017


Specific material removal rate q' is calculated for 5-axis grinding in a virtual machining simulation environment (VMSE). The axis-symmetric tool rotational profile is arc-length parameterized. The twisted grazing curve due to the concurrent translation and rotation in every move is modeled through an exact velocity field and areal material removal rate density q'' formulation on the tool surface. Variation of q' and equivalent chip thickness h within the instantaneous engagement contour is calculated considering its portion in the front of the grazing curve. Illustrative results with a 5 - axis impeller blade finishing simulation are shown. The results were benchmarked against an average q' calculated from the instantaneous material removal rate from the VMSE. As a function of time, maximum chip thickness hmax within the extents of contact along the tool profile in every move showed more isolated peaks than corresponding q'max. Maximum cumulative material removed per unit length Q'max along the tool profile from all the moves was calculated to predict axial location of maximum risk of cutter degradation. Q'max and hmax are useful metrics for tool path diagnosis and tool wear analysis.

United Technologies Corporation
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