Optimising the grinding wheel design for flute grinding processes utilising numerical analysis of the complex contact conditions
More details
Hide details
Institute for Machine Tools and Factory Management (IWF) – TU Berlin, Germany
Submission date: 2019-12-03
Acceptance date: 2020-02-12
Online publication date: 2020-09-25
Publication date: 2020-09-25
Journal of Machine Engineering 2020;20(3):85–94
Resource efficiency is gaining relevance in every aspect of production. Hence, cutting tools are exposed to high demands regarding productivity and quality. Considering the various grinding operations in tool manufacturing, flute grinding is the most significant process step as it defines the peripheral cutting edge and the rake face. Therefore, it has a substantial influence on the machining behaviour of, for example, milling tools. When it comes to helical flutes, the complex contact conditions between grinding wheel and tool blank during the multiaxial grinding process are particularly difficult to determine. Due to the lack of knowledge about those contact conditions, the grinding wheels typically used for flute grinding cannot wholly meet the actual process requirements. In order to optimise the design of the grinding wheels, a numerical model was developed. Based on that, a simulation tool was implemented to analyse the complex contact conditions during flute grinding depending on the process parameters and tool/workpiece geometry. The influence of different grinding parameters on the effective contact length, the specific material removal rate and the equivalent chip thickness was evaluated by employing the computer-based model. The generated results were then used to develop a new optimised tool concept for a more efficient flute grinding process.
BEJU L.D., BRINDASU D.P., MUTIU N.C., ROTHMUND J., 2016, Modeling, simulation and manufacturing of drill flutes, International Journal of Advanced Manufacturing Technology, 83/9, 2111–2127.
CHIANG C.J., FONG Z.H., TSENG J.T., 2009, Computerized simulation of thread from grinding process, Mechanism and Machine Theory, 44/4, 685–696.
DENKENA B., TRACHT K., DEICHMÜLLER M., 2006, Wechselwirkungen zwischen Struktur und Prozess beim Werkzeugschleifen, wt Werkstattstechnik online, 11/12, 814 819.
DENKENA B., HOLLMANN F., 2013, Process Machine Interactions – Prediction and manipulation of interactions between manufacturing processes and machine tool structures, Berlin, Heidelberg, Springer.
EHMANN K.F., DE VRIES M.F., 1990, Grinding wheel profile definition for the manufacture of drill flutes, CIRP Annals – Manufacturing Technology, 39/1, 153–156.
FRIEDMANN M.Y., BOLSELAVSKI M., MEISTER I., 1972, The Profile of a helical slot machined by a disk-type cutter with an infinitesimal width, considering undercut-ting, Proceedings of the 13th International Machine Tool Design Research Conference, 245–246.
HSIEH J., 2006, Mathematical model and sensitivity analysis for helical groove machining, International Journal of Machine Tools and Manufacture, 46/10, 1087–1096.
HÜBERT C., 2012, Schleifen von Hartmetall- und Vollkeramik-Schaftfräsern, Berichte aus dem Produktionstechnischen Zentrum Berlin, Berlin, Fraunhofer Verlag.
KALDOR S., RAFAEL A.M., MESSINGER D., 1988, On the CAD of profiles for cutters and helical flutes – Geometrical aspects, CIRP Annals – Manufacturing Technology, 37/1, 53–56.
KANG S.K., EHMANN K.F., LIN C., 1996, A CAD approach to helical groove machining – I. Mathematical model and model solution, International Journal of Machine Tools and Manufacture, 36/1, 141–153.
KASSEN G., 1969, Beschreibung der elementaren Kinematik des Schleifvorgangs, Rheinisch-Westfälische Technische Hochschule, Aachen, Diss.
KIM J.H., PARK J.W., KO T.J., 2008, End mill design and machining via cutting simulation, Computer-Aided Design, 40/3, 324–333.
LI G., SUN J., LI J., 2014, Modeling and analysis of helical groove grinding in end mill machining, Journal of Materials Processing Technology, 214/12, 3067–3078.
MOHAN L.V., SHUNMUGAM M.S., 2004, CAD approach for simulation of generation machining and identification of contact lines, International Journal of Machine Tools & Manufacture, 44, 717–723.
SHETH E., MALKIN S., 1990, CAD/CAM for geometry and process analysis of helical groove machining, CIRP Annals – Manufacturing Technology 39/1, 129–132.
SUN Y., WANG J., GUO D., ZHANG Q., 2006. Modeling and numerical simulation for the machining of helical surface profiles on cutting tools, The International Journal of Advanced Manufacturing Technology, 36, 525–534.
UHLMANN E., HÜBERT C., 2011, Tool Grinding of End Mill Cutting Tools Made from High Performance Ceramics and Cemented Carbides, CIRP Annals, 60, 359–362.
WANG L., CHEN Z.C., LI J., SUN J., 2016, A novel approach to determination of wheel position and orientation for five-axis CNC flute grinding of end mills, International Journal of Advanced Manufacturing Technology, 84/9, 2499–2514.
WERNER G., 1971, Kinematik und Mechanik des Schleifprozesses, Rheinisch-Westfälische Technische Hochschule Aachen, Diss.