Research Papers

Specific Material Removal Rate Calculation in Five-Axis Grinding

[+] Author and Article Information
Raja Kountanya

Pratt & Whitney,
400 Main Street, MS114-42,
East Hartford, CT 06118
e-mail: raja.kountanya@pw.utc.com

Changsheng Guo

United Technologies Research Center,
411 Silver Lane MS129-22,
East Hartford, CT 06108
e-mail: guoc@utrc.utc.com

Manuscript received March 30, 2017; final manuscript received September 19, 2017; published online November 2, 2017. Assoc. Editor: Mark Jackson.

J. Manuf. Sci. Eng 139(12), 121010 (Nov 02, 2017) (6 pages) Paper No: MANU-17-1193; doi: 10.1115/1.4037969 History: Received March 30, 2017; Revised September 19, 2017

Specific material removal rate (MRR) q was calculated for five-axis grinding in a virtual machining simulation environment (VMSE). The axis-symmetric tool rotational profile was arc-length parameterized. The twisted grazing curve due to the concurrent translation and rotation in every move was modeled through an exact velocity field and areal MRR density q, positive in the front of the grazing curve on the tool surface. Variation of q and equivalent chip thickness h within the instantaneous engagement contour were deduced from q. Illustrative results with a five-axis impeller blade finishing simulation are shown. The results were benchmarked against an average q calculated from the instantaneous MRR 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 qmax. Maximum cumulative material removed per unit length Qmax along the tool profile from all the moves was calculated to predict axial location of maximum risk of cutter degradation.  Qmax and hmax are useful metrics for tool path diagnosis and tool wear analysis.

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Fig. 1

q′ for simple surface grinding

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Fig. 2

(a) Tool rotational profile and (b) schematic for five-axis motion

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Fig. 3

Components of contact in s−ϕ

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Fig. 4

Schematic for three-axis motion. Ss,ϕ given in Eq. (1)

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Fig. 8

Five-axis model results: (a) q′ distribution for various instants t and (b) Q′ (solid line), q′ (dots)

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Fig. 7

Five-axis model results of toolpath in Fig. 6: (a) qMRR′, qmax′ and qave′ and (b) hmax and have

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Fig. 6

Impeller blade finishing: angle between start and end tool axes

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Fig. 5

Parallels of s between engagement contour points



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