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 Manufacturing Model of S-Shaped Ball-Nosed Milling Cutter and Error Analysis in Realisation in Industry
The paper first discusses the reasons for studying and manufacturing ball-nosed milling cutters with S-shaped cutting edges. Then, based on prior studies, and through introducing a helicoid, it presents a new manufacturing model used to grind the rake face and flank of the cutter. The amplitude of |Δs| machined via this model is much larger than that machined via other models. A special mechanism is also presented for grinding the flank of the cutter. Furthermore, to ensure the feasibility of manufacturing a ball-nosed milling cutter, error models are studied from four main aspects and interpreted in the text in detail. The mathematical formulae of the error models are presented, and a numerical example is also presented to illustrate the effectiveness of the proposed modelling procedure. The example includes the machining data and error scale of each main parameter. Those data indicate that the proposed model and grinding procedure are capable of producing the ball-nosed milling cutters with an accuracy conforming to the user-provided specific tolerance.
A manufacturing model of carbide-tipped spherical milling cutters
Abstract The paper presents a manufacturing model for use in grinding the front-end surfaces of a carbide-tipped spherical milling cutter. The concepts of radial equidistant lines and oblique equidistant surfaces are presented. Based upon these concepts, a model of the cutting edge of a spherical milling cutter is derived by solution for the intersection of the spherical front-end surface of the cutter and the equation of a sphere. A special mechanism model is also presented for grinding the rear cutting-edge surface of the cutter. To ensure that the mechanism model is valid, the cutting-edge curve of the cutter is also on the rear cutting-edge surface. The associated geometric and manufacturing parameters are further optimized to ensure that the best quality of the carbide-tipped spherical milling cutter can be achieved. The mechanism is also used to study the manufacturability of spherical milling cutters for slightly varying specifications. A numerical example is presented to illustrate the effectiveness of the proposed modelling procedure for producing carbide-tipped spherical milling cutters. Numerical results indicate that the proposed manufacturing model and grinding procedure are capable of producing a family of carbide-tipped spherical milling cutters with an accuracy up to the user-provided specific tolerance. Some major contributions of the proposed approach are summarized in the conclusions.