This paper presents a mathematical model to find the wheel location in grinding a given helical flute of an end mill. Two new setting parameters are introduced to define the relative wheel location in workpiece coordinates. This model allows the wheel-axis orientation be expressed explicitly as a function of the design factors and machine setting parameters. By utilizing this explicit form of the wheel orientation and analyzing the influence of setting parameters on design parameters, a new efficient search algorithm is proposed, and the performance shows that the required wheel location is found within 1.5 s to machine a given flute profile. Moreover, the rake angle can be produced more precisely compared with the conventional methods, which have been used with approximations. A comprehensive development of the software for designing and grinding the helical flute of the end mill is presented, which provides a technology and good foundation for the development of a computer-aided design and computer-aided manufacturing (CAD/CAM) system for manufacturing end mills. The results of the experiment, simulation, and design are compared in order to verify of the proposed method.
A New Method for Determination of Wheel Location in Machining Helical Flute of End Mill
Manuscript received June 9, 2015; final manuscript received March 23, 2016; published online June 23, 2016. Assoc. Editor: Guillaume Fromentin.
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Nguyen, V., and Ko, S. (June 23, 2016). "A New Method for Determination of Wheel Location in Machining Helical Flute of End Mill." ASME. J. Manuf. Sci. Eng. November 2016; 138(11): 111003. https://doi.org/10.1115/1.4033232
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