A Grinding Trajectory Accurate Calculation Method for Circular-arc End Mill Flanks Based on Contact Area Adaptive Adjustment

doi:10.3969/j.issn.1004-132X.2024.07.010

Abstract

Abstract: In order to ensure the machining accuracy of circular-arc end mill flanks, a grinding trajectory accurate calculation method for circular-arc end mill flanks was proposed based on contact area adaptive adjustment. Firstly, the mathematical model of the flank was constructed through structural feature decomposition of the circular-arc end mill. Then, by calculating the grinding contact area between the grinding wheel and the flank, the grinding wheel posture was adaptively corrected to avoid grinding interference, which realized the accuracy and consistency of flank geometric parameter control and ensured the smooth connection of the curved surfaces. Finally, based on the implement of VC++ platform algorithm module, the effectiveness of the proposed algorithm was verified by machining simulation and grinding experiments.

Key words: circular-arc end mill, flank, grinding trajectory, contact zone, adaptive adjustment

摘要： 为保证圆弧头立铣刀后刀面的加工精度，提出一种基于接触区域自适应调整的圆弧头立铣刀后刀面磨削轨迹精确计算方法。通过圆弧头立铣刀结构特征分解构建了后刀面的数学模型；通过计算砂轮和后刀面之间的磨削接触区域，自适应修正砂轮姿态，避免磨削干涉，实现了后刀面几何参数控制的准确性和一致性，并保证了曲面的光滑连接。最后，在VC++平台算法模块开发的基础上，通过加工仿真和磨削试验验证了该算法的有效性。

关键词: 圆弧头立铣刀, 后刀面, 磨削轨迹, 接触区域, 自适应调节

CLC Number:

TH162
TH164

LIU Zhe1, YANG Decun1, 2, YANG Zhihui1, JIANG Lei1. A Grinding Trajectory Accurate Calculation Method for Circular-arc End Mill Flanks Based on Contact Area Adaptive Adjustment[J]. China Mechanical Engineering, 2024, 35(07): 1222-1231，1240.

刘哲1, 杨德存1, 2, 阳智麾1, 江磊1. 基于接触区域自适应调整的圆弧头立铣刀后刀面磨削轨迹精确计算方法[J]. 中国机械工程, 2024, 35(07): 1222-1231，1240.

References

［1］陈涛, 李显创, 王广越, 等. 带圆角圆弧头铣刀设计的关键技术［J］. 哈尔滨理工大学学报, 2017, 22(1):75-79.
CHEN Tao, LI Xianchuang, WANG Guangyue, et al. The Key Technology of Torus End Milling Cutter with Circular Corner Design［J］. Journal of Harbin University of Science and Technology, 2017, 22(1):75-79.
［2］CHEN Tao, LIU Xianli, WANG Changhong, et al. Design and Fabrication of Double-circular-arc Torus Milling Cutter［J］. The International Journal of Advanced Manufacturing Technology, 2015, 80(1/4):567-579.
［3］HAN Lei, CHENG Xuefeng, JIANG Lei, et al. Research on Parametric Modeling and Grinding Methods of Bottom Edge of Toroid-shaped End-milling Cutter［J］. Proceedings of the Institution of Mechanical Engineers, Part B:Journal of Engineering Manufacture, 2019, 233(1):31-43.
［4］HE Lilun, WANG Xibin, LIU Zhibing, et al. Mathematical Modeling and Parametric Design of Taper End Mills［J］. Advanced Materials Research, 2013, 797:574-578.
［5］XIN Quanqi, WANG Taiyong, YU Zhiqiang, et al. Grinding Process of Ball End Milling Cutter Flank［J］. Key Engineering Materials, 2018, 764:383-390.
［6］NGUYEN H, KO S L. A Mathematical Model for Simulating and Manufacturing Ball End Mill［J］. Computer-Aided Design, 2014, 50:16-26.
［7］WASIF M, IQBAL S A, AHMED A, et al. Optimization of Simplified Grinding Wheel Geometry for the Accurate Generation of End-mill Cutters Using the Five-axis CNC Grinding Process［J］. The International Journal of Advanced Manufacturing Technology, 2019, 105(10):4325-4344.
［8］刘建军, 黎荣, 程雪锋, 等. 圆弧头立铣刀端刃CNC磨削仿真技术研究［J］. 现代制造工程, 2012(10):84-89.
LIU Jianjun, LI Rong, CHENG Xuefeng, et al. Research on CNC Grinding Simulation Technology of Torus End Milling Cutters End Edges［J］. Modern Manufacturing Engineering, 2012(10):84-89.
［9］马玉豪, 宁样城, 丁国富, 等. 基于砂轮磨损参数的立铣刀后刀面磨削轨迹补偿算法［J］. 工具技术, 2021, 55(3):47-51.
MA Yuhao, NING Yangcheng, DING Guofu, et al. Algorithm for Flank Grinding Track Compensation of End Mill Based on Wheel Wear Parameter［J］. Tool Engineering, 2021, 55(3):47-51.
［10］MA Yuhao, LI Yong, JIANG Lei, et al. A Compensation Algorithm of Tool Path for Grinding Wheel Wear in Solid Cutting Tool Flank Grinding［J］. Proceedings of the Institution of Mechanical Engineers, Part B:Journal of Engineering Manufacture, 2022, 236(3):245-254.
［11］唐军, 马忠宝, 罗斌, 等. 平行砂轮磨削圆弧头立铣刀后刀面的轨迹算法［J］. 制造技术与机床, 2021(9):86-91.
TANG Jun, MA Zhongbao, LUO Bin, et al. Trajectory Algorithm of Grinding Flank Face of Arc End Milling Cutter with Parallel Grinding Wheel［J］. Manufacturing Technology & Machine Tool, 2021(9):86-91.
［12］CHENG Xuefeng, DING Guofu, LI Rong, et al. A New Design and Grinding Algorithm for Ball-end Milling Cutter with Tooth Offset Center［J］. Proceedings of the Institution of Mechanical Engineers, Part B:Journal of Engineering Manufacture, 2014, 228(7):687-697.
［13］WANG Guixin, XU Changlei. A Practical CNC Grinding Algorithm for Ball-end Mill and the Opengl Simulation of the Algorithm［J］. IOP Conference Series:Materials Science and Engineering, 2018, 394:032027.
［14］KIM J H, PARK J W, KO T J. End Mill Design and Machining via Cutting Simulation［J］. Computer-Aided Design, 2008, 40(3):324-333.
［15］CHEN Fengjun, HU Sijie, YIN Shaohui. A Novel Mathematical Model for Grinding Ball-end Milling Cutter with Equal Rake and Clearance Angle［J］. The International Journal of Advanced Manufacturing Technology, 2012, 63(1/4):109-116.
［16］YANG Jianping, WANG Liming, FANG Yang, et al. A Novel Approach to Wheel Path Generation for 4-axis CNC Flank Grinding of Conical End-mills［J］. The International Journal of Advanced Manufacturing Technology, 2020, 109(1/2):565-578.
［17］JI Wei, LIU Xianli, WANG Lihui, et al. Research on Modelling of Ball-nosed End Mill with Chamfered Cutting Edge for 5-axis Grinding［J］. The International Journal of Advanced Manufacturing Technology, 2016, 87(9/12):2731-2744.
［18］马玉豪, 李勇, 江磊, 等. 断屑钻尖后刀面的砂轮磨削位姿算法［J］. 中国机械工程, 2021, 32(19):2321-2325.
MA Yuhao, LI Yong, JIANG Lei, et al. Wheel-grinding Position and Pose Algorithm of Flank Faces of Cutting-breaking Drill Tips［J］. China Mechanical Engineering, 2021, 32(19):2321-2325.

[1]	CHEN Zhongbao, HAN Xinghui, ZHUANG Wuhao, HU Yaxiong, CHEN Mingzhang, . Forming Law of Multi-degree-of-freedom Rotary Forging for High-rib Thin-plate Components and Process Planning [J]. China Mechanical Engineering, 2023, 34(04): 464-474.
[2]	WANG Chengbing, XIONG Jianjun, JIANG Lei, MA Shuwen. Research on Wheel Grinding Trajectory Algorithm of Straight Blade Flank Faces of Drill Tips [J]. China Mechanical Engineering, 2022, 33(16): 1906-1911.
[3]	MA Yuhao, LI Yong, JIANG Lei, DING Guofu. Wheel-grinding Position and Pose Algorithm of Flank Faces of Cutting-breaking Drill Tips [J]. China Mechanical Engineering, 2021, 32(19): 2321-2325,2330.
[4]	YU Hangzhuo1;QIN Shengfeng1,2;DING Guofu1;JIANG Lei1;LIANG Hongqin1. Research on Prediction Technology for Tool Rotation Profile Errors in Flank Milling [J]. China Mechanical Engineering, 2020, 31(03): 306-313.
[5]	NIE Shaowu1,2;JIANG Chuang2;DENG Xiaozhong2;SU Jianxin2;YANG Jianjun1;WANG Jianhua3. Flank Modification Method of Hypoid Gears with Ease-off Topology Correction [J]. China Mechanical Engineering, 2019, 30(22): 2709-2715,2740.
[6]	LIU Hongjun1;WEI Yuxiang2. Tool Axis Trajectory Plannings for Flank Milling Based on AFS-PSO Hybrid Algorithm [J]. China Mechanical Engineering, 2018, 29(23): 2815-2820.
[7]	Hu Dongfang, Zhang Wenbo. Flank Milling Cutter Path Optimization Method in Spatial Cam Machining Based on Reconstruction of NURBS Ruled Surface Driven by Sensitive Points [J]. China Mechanical Engineering, 2016, 27(14): 1917-1924.
[8]	Zhou Xin, Li Yingguang, Liu Hao, Liu Changqing. A Feature-based Cutting Force Fast Prediction and Evaluation for Complex Aircraft Structure Parts [J]. China Mechanical Engineering, 2015, 26(7): 886-891.
[9]	Yu Daoyang, Han Jiang, Zhao Han. High Precision Machining Technology Based on Analytical Method for Integral Impeller with Flank Milling [J]. China Mechanical Engineering, 2015, 26(3): 304-307.
[10]	Wang Hongwei, Chen Guo, Li Ai, Chen Libo. An Adaptive Adjustment Technique of Multi-parameters in Microimaging System [J]. China Mechanical Engineering, 2014, 25(24): 3338-3342.
[11]	ZHANG Li-Jiang-1, WANG Ke-Yong-1, WANG Yu-Han-2. Kinematical Optimum Method for Five-axis Flank Milling Complex Surfaces [J]. China Mechanical Engineering, 2011, 22(21): 2588-2593.
[12]	FAN Hong-Zhou, XI Guang, WANG Chang-Jin. Algorithm for 5-axis Numerical Control Flank Milling of Arbitrary Surfaces Fan Hongzhou;Xi Guang;Wang Shangjin [J]. China Mechanical Engineering, 2010, 21(02): 127-130.
[13]	Liu Xingwang，;Liu Zhenquan;Qi Xueyi. Research on Scroll Compressor’s Flank Sealing Structure Based on Labyrinth Effect [J]. J4, 2009, 20(20): 0-2519.
[14]	Zhou Zhixiong ;Mao Cong;Zhou Dewang;Ren Yinghui. Experimental Investigation of Grinding Temperature and Its Effects on Surface Quality in Surface Grinding  [J]. J4, 2008, 19(8): 0-888,.