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Optimising the grinding wheel design for flute grinding processes utilising numerical analysis of the complex contact conditions

Uhlmann Eckart, Gülzow Bernhard, Muthulingam Arunan

Journal of Machine Engineering

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2020

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Vol. 20, No. 3

85--94

EN

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.

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Investigation on the Dynamics of Tool Grinding

Payrebrune K. M., Kröger M., Deichmueller M., Denkena B.

Machine Dynamics Problems

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2009

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Vol. 33, No. 2

92-104

EN

The manufacturing of high-performance carbide tools, like drills or milling cutters, is realized by a grinding process because of the strength and hardness of the used material. Due to the process forces and the cantilevering clamped workpiece, the blank bends and unwanted geometry errors occur. Additionally, great efforts are made to find optimal parameters for stable process conditions. In this work the interaction phenomena of tool grinding process and machine structure are analyzed and modelled. Thereby, the dynamic behaviour of workpiece, grinding wheel, and machine structure is experimentally investigated. Additionally, force signals of the grinding processes are measured and analyzed in time and frequency domain.

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Development of database and searching system for tool grinding

Chen J. Y., Lin W. Y., Lee B. Y., Chen C. H.

Journal of Achievements in Materials and Manufacturing Engineering

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2008

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Vol. 26, nr 2

159-162

EN

Purpose: For achieving the goal of saving time on the tool grinding and design, an efficient method of developing the data management and searching system for the standard cutting tools is proposed in this study. Design/methodology/approach: At first the tool grinding software with open architecture was employed to design and plan grinding processes for seven types of tools. According to the characteristics of tools (e.g. types, diameter, radius and so on), 4802 tool data were established in the relational database. Then, the SQL syntax was utilized to write the searching algorithms, and the human machine interfaces of the searching system for the tool database were developed by C++ Builder. Findings: For grinding a square end mill with two-flute, a half of time on the tool design and the change of production line for grinding other types of tools can be saved by means of our system. More specifically, the efficiency in terms of the approach and retract time was improved up to 40%, and an improvement of approximately 10.6% in the overall machining time can be achieved. Research limitations/implications: In fact, the used tool database in this study only includes some specific tools such as the square end mill. The step drill, taper tools, and special tools can also be taken into account in the database for future research. Practical implications: The most commercial tool grinding software is the modular-based design and use tool shapes to construct the CAM interface. Some limitations on the tool design are undesirable for customers. On the contrary, employing not only the grinding processes to construct the grinding path of tools but the searching system combined with the grinding software, it gives more flexible for one to design new tools. Originality/value: A novel tool database and searching system is presented for tool grinding. Using this system can save time and provide more convenience on designing tools and grinding. In other words, the company productivity can be improved.