CAD tool development of end mill parameter design based on DA method
It is given that the problem of computing complexity in end mill design when determines the geometric parameters of end mill, e.g., cutter edge's rake angle and relief angle etc., a method of 3D solid modeling method (called as Direct Analysis, DA) is applied in an end mill CAD package development. The related mathematic formulas of cutter edges are discussed here by which can be used for dynamically creating a 3D cutter with expected geometric parameters by through analyzing end mill geometric parameters, visualizing the process of grinding wheel cutting mill cutter, and then a prototype program for end mill parameter design was developed which it integrates HOOPs 3D display component as supporting module. The main modules' function and relationship of the prototype are discussed as well. It is verified with some historic data that it is feasible to design and chose the optimized parameters during end mill design.
Grinding Wheel Profile Definition for the Manufacture of Drill Flutes
Abstract A purely analytical approach, based on the principles of differential geometry and kinematics, is presented for the solution of the inverse problem for the manufacture of drill flutes. The mathematical relationships established facilitate the determination of the grinding wheel profile for a given radial drill flute cross-section. Examples, generated by an interactive grinding wheel design program, are discussed.
A Cutting Simulation System for Machinability Evaluation Using a Workpiece Model
Abstract This paper describes a cutting simulation system to be used in the evaluation of machinability of products at various stages of the manufacturing processes. The system developed consists of geometric simulation and physical simulation. The geometric simulation is performed by using extended Z buffer models representing a workpiece and a tool swept volume. In the physical simulation, instantaneous cutting force vectors acting on a square end mill are computed based on the am of chip element removed by a thin divided section of a flute. The tool deflection induced by the cutting force is then calculated. The result is used to estimate the machining error caused by tool deflection. A series of cutting experiments are conducted to verify the effectiveness of the system.