Research on virtual manufacturing models of a new type of taper ball-end milling cutter
Based on the analysis of the difficulties in design and manufacturing and cutting edge curves of many kinds of revolving milling cutters, a design method is presented in this paper for a new type of cutting-edge. The general differential equation is given so that the cutting-edge, the three-grooves and the grinding wheel to grind can be satisfied. The actual grooves and cutting-edges of virtual manufacturing are presented. The general feeding speeds of grinding wheel used in 2-axis NC machining of the cutter were deduced. The virtual simulation of the taper ball-end cutter is carried out. It has been proved that the traditional problems in designing and manufacturing are solved successfully in this way, simultaneously the process is much simple for it can be formed only in one time elementarily.
A new design and grinding algorithm for ball-end milling cutter with tooth offset center
Ball-end milling cutter with tooth offset center is widely used in machining industry, because it has higher machining efficiency and better stability compared with the ball-end milling cutter without tooth offset center. In addition, the tooth offset center has lower wear rate of the tool tip so the life of the milling cutter is improved. However, up to present, there is no mature and effective theory for the design and manufacture of this kind of milling cutters. This article presents a new mathematical model for S-shaped edge curve of the ball end taking the tooth offset center into account, which can construct accurate S-shaped edge curve for the ball-end cutting tools with tooth offset center as well as without tooth offset center. This model overcomes the complex computation and bad adaptability of the traditional modeling method. At the same time, a five-axis grinding algorithm for rake face of the ball end is also presented in this article. Finally, based on the application programming interface of CATIA™, a three-dimensional computer-aided design and computer-aided manufacturing system is developed. The accuracy and effectiveness of the grinding algorithm are verified by simulation in VERICUT™ and machining experiment in tool grinding machine.
Study on Geometrical Model for Modifying and Grinding the Ball End Cutter
A manufacturing model for the ball end cutter is presented, and the feasibility of grinding ball end cutters of different sizes using the same mechanism is discussed. The concept of slant offset surface and associated formulas are proposed for utilizing the existing grinding mechanism. Details of its application in modifying and grinding the ball end cutter and its geometrical model related to the manufacturing process are introduced. Test results confirm the feasibility and reliability of the presented model.