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A simple geometric and optimal method is adopted for the five-axis CNC grinding of the end-mill cutters. In this research, initially a simplified parametric profile of the grinding wheel is constructed using line segments and circular arcs. The equation of the wheel swept-surface in five-axis grinding is derived. Then subjected to the flute profile...
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Citations
... Shen et al. [19] studied the relationship between the grinding wheel profile and different helical flutes on the existing helical rake face. Wasif et al. [20] proposed an optimization algorithm for grinding wheel profile based on the differential evolution algorithm. Forbrigger et al. [21] extended the existing fluted grinding wheel theory to the grinding wheel profile and described a generalized method for calculating the flute factor for the grinding wheel. ...
... (3) The rotation angle ξ 3 of the point Q 3 Denote the radius of the grinding wheel profile corresponding to point Q 3 as R g3 , as shown in Fig. 6 (c). The disc is tangent to the tool cylindrical surface, so R g3 could be approximated by Eq. (20). ...
The forming grinding process is a crucial method for helical flute grinding of the end mill and screw tap, and the grinding wheel profile is the key to ensure the precision of the helical flute, which is constrained by the grinding wheel posture. However, the existing methods have some deficiencies such as the invalidity or uneven wear problems. In this paper, an optimized calculation method of the grinding wheel profile for the forming grinding of the helical flute is proposed, including the suitable grinding posture correspondingly. Firstly, the parametric models of the helical cutting edge and the helical flute surface are established. Secondly, the contact condition between the grinding wheel and the flute is deduced to calculate the grinding wheel profile by the envelop theory. Thirdly, an optimization method for grinding wheel profile is proposed, which could predict of the solution interval, avoid the profile intersection, and improve wear resistance. Finally, the method was verified by a series of simulations and experiments, and the results show that the method could meet the grinding precision requirements and expand the application range of forming grinding technology in helical flute.
... To date, grinding is still one of the best choices and the most frequently used methods for processing hard materials, due to its simplicity, high machining quality, and cost efficiency [16]. In grinding, the workpiece material is removed by the protruded grits distributed on the working surface of the grinding wheel, and many factors, including the grinding parameters [17,18], wheel geometry [19,20], grit size [21,22], lubrication [23,24], workpiece material properties [25], dressing condition [26], and vibrations [16,27], influence the surface generation processes, determining the final surface quality. In order to optimize the grinding process to obtain good surface quality, it is important to study the surface generation process in grinding. ...
Hard materials have found extensive applications in the fields of electronics, optics, and semiconductors. Parallel grinding is a common method for fabricating high-quality surfaces on hard materials with high efficiency. However, the surface generation mechanism has not been fully understood, resulting in a lack of an optimization approach for parallel grinding. In this study, the surface profile formation processes were analyzed under different grinding conditions. Then, a novel method was proposed to improve surface finish in parallel grinding, and grinding experiments were carried out to validate the proposed approach. It was found that the denominator (b) of the simplest form of the rotational speed ratio of the grinding wheel to the workpiece has a great influence on surface generation. The surface finish can be optimized without sacrificing the machining efficiency by slightly adjusting the rotational speeds of the wheel or the workpiece to make the value of b close to the ratio (p) of the wheel contact width to the cross-feed distance per workpiece revolution. Overall, this study provides a novel approach for optimizing the parallel grinding process, which can be applied to industrial applications.
... However, these considerations mainly refer to flute grinding of end mills so for consideration in this paper served [12]. Brazed carbide profile mill cutters for machining of wood, wood materials are built today using costly 5-axis grinding machines [13,14] supported by specialized CAM software that is very expensive too. ...
... The tool tip coordinates T i can be determined, as shown in Fig. 13, based on the coordinates of the profile points K pi ,i.e., cutting edge points K ei , unit vectors of the normal in those points n i , unit vector a defined by the grinding wheel orientation angle B and the grinding wheel rounding radius r . For known coordinates of the contact points CC i , coplanar unit vectors n i and a i and grinding wheel rounding radius r , given that y wpi = y wei = y wti = 0, according to Fig. 13, the vector equation of the plane can be derive p T i = p CCi + r · n i − r · a = p CCi + r · (n i − a) (14) Since according to (13), due to the specified constant orientation angle B, the vector components a are constant such as a = cos B 0 sin B T and the vector components n = cosϕ i 0 sinϕ i T are different in each profile point, according to (14), the and tool tip coordinates T i are obtained as The procedure of determining tool tip coordinates T i , according to (15), in discrete points of the rectilinear and circular segments, has to be corrected in nodal points with two normals n i and n i . The examples indicating for the necessity of correction at nodal point K pi from Fig. 14 whose tool tip T i for the normal n i in moving to the position T i for the normal n i would lead to truncating the profile. ...
... The tool tip coordinates T i can be determined, as shown in Fig. 13, based on the coordinates of the profile points K pi ,i.e., cutting edge points K ei , unit vectors of the normal in those points n i , unit vector a defined by the grinding wheel orientation angle B and the grinding wheel rounding radius r . For known coordinates of the contact points CC i , coplanar unit vectors n i and a i and grinding wheel rounding radius r , given that y wpi = y wei = y wti = 0, according to Fig. 13, the vector equation of the plane can be derive p T i = p CCi + r · n i − r · a = p CCi + r · (n i − a) (14) Since according to (13), due to the specified constant orientation angle B, the vector components a are constant such as a = cos B 0 sin B T and the vector components n = cosϕ i 0 sinϕ i T are different in each profile point, according to (14), the and tool tip coordinates T i are obtained as The procedure of determining tool tip coordinates T i , according to (15), in discrete points of the rectilinear and circular segments, has to be corrected in nodal points with two normals n i and n i . The examples indicating for the necessity of correction at nodal point K pi from Fig. 14 whose tool tip T i for the normal n i in moving to the position T i for the normal n i would lead to truncating the profile. ...
Brazed carbide profile mill cutters are widely used in the machining of wood, wood materials, and plastic to form various functional and aesthetic surfaces. Tools of this kind are used in serial and mass production and they are built today using very costly 5-axis grinding machines supported by specialized CAM software that is very expensive too. The paper first developed the possible concept of 5-axis grinding of brazed profile mill cutters using universal diamond grinding wheel shapes. The developed concept of 5-axis grinding served as a basis for the developed approach for 3+2-axis grinding of the brazed form mill cutters which is the essence of this paper. Verification of this set approach of 3+2-axis grinding is performed on a developed functional prototype of a simple 3+2-axis grinder (Axes XYZ are CNC controlled, axes B and C are unpowered axes and have fixed positions during grinding). Based on the established 3+2 grinding strategy complete grinding of a complex profile has been performed on a developed functional prototype. Shape and measures of the cutting edge profile achieved by grinding are inspected on an optical measuring system and showed exceptional results. The established 3+2-axis method of grinding is an economically successful alternative to costly 5-axis grinding machines, as well as to specialized software, presented in the paper through experimental and practical application.
... Therefore, the machining origin between the workpiece and tool is de ned during operation, and a reference surface is required that can de ne the origin coordinates. [16][17][18][19][20] However, due to the irregular surface of WAAM-manufactured structures it is di cult to determine the origin coordinates. In addition, it is di cult to accurately predict the shape of the workpiece when designing a machining path using computer-aided manufacturing (CAM). ...
Wire arc additive manufacturing (WAAM) is a metal 3D printing process that uses arc welding. It is a method of stacking beads made by melting metal wires with an arc heat source generated by a short-circuit current. Compared to other metal additive manufacturing methods, this process can be used to quickly produce large and complex-shaped metal parts. However, due to the multi-bead stacking method, the surface is highly curved and the dimensional errors are large; therefore, post-processing of the surface by cutting is required. Impellers, which are widely used in various industries, have complex shapes and high material consumption during cutting; therefore, the WAAM process can improve the manufacturing efficiency. In this study, a manufacturing process for an impeller with a diameter of 160 mm was developed by using the WAAM process. A 6-bladed fan-type impeller used for high-pressure fluid delivery was similarly modeled, and the product was additively manufactured using an Inconel 625 alloy wire. The additive manufacturing conditions that ensure productivity and quality or the product were determined through experimentation. Considering the post-processing of the WAAM-fabricated structure, the robot and tool paths of the impeller model were designed, and the error in the process coordinate system caused by attaching and detaching the workpiece between the two processes was reduced. Through the post-processing of the WAAM-fabricated structure, the production efficiency and process reliability were verified when the conventional manufacturing method and WAAM process were applied.
... Shen et al. [16] studied the relationship between grinding wheel profile and different helical flutes on the existing helical rake face. Wasif et al. [17] proposed an optimization algorithm for grinding wheel profile based on the differential evolution algorithm. ...
Forming grinding process is a crucial method for grinding the helical flute of end mills, and the calculation of the grinding wheel profile is the key to ensure the precision of the helical flute, which is constrained by grinding wheel posture and helical flute profile. However, the current calculation method has not done enough research on the estimation of the feasibility and validity of the grinding wheel profile, which could lead to contradiction between theoretical calculations and practical application. In this paper, an optimized calculation method of the grinding wheel profile for the helical flute forming grinding is proposed, which includes the calculation, analysis and optimization process. Firstly, the parameters of the helical cutting edge and the flute surface are defined, and accurate geometrical models are established. Secondly, the contact condition between the grinding wheel and the flute surface is deduced to calculate the grinding wheel profile by the envelop theory. Thirdly, an optimization method, including profile optimization and grinding wheel wear optimization, is proposed for the calculation of the grinding wheel profile. Finally, the method is verified by simulation machining and the results show that the method can improve the grinding precision and expand the application range of forming grinding technology in helical flute grinding.
... Grinding technology is used extensively in advanced industries for producing mechanical components with superfinishing characteristics. Examples of these products include the grinding of cutting tools (twist drills, 20,21 milling Cutters, 22,23 broaching tools, 24 threads, 25,26 gears, [27][28][29] brake discs, 30,31 Fig. 3 Classification of grinding processes. ...
Grinding technology is an essential manufacturing operation, in particular, when a component with a superfinishing and an ultra-resolution is yearned. Meeting the required strict quality checklist with maintaining a high level of productivity and sustainability is a substantive issue. The recent paper outlines the lubrication and cooling technologies and mediums that are used for grinding. Furthermore, it provides a basis for a critical assessment of the different lubrication/cooling techniques in terms of machining outputs, environmental impact, hygiene effect, etc. Meanwhile, the paper put light on the sustainability of different cooling/lubrication strategies. The sustainability of machining aims to get the product with the best accuracy and surface quality, minimum energy consumption, low environmental impact, reasonable economy, and minimum effect on worker’s health. The paper revealed that despite some cooling/lubrication mediums like mineral oils and semisynthetic, afford sufficient lubrication or cooling, they have a significant negative impact on the environment and public health. On the other hand, emulsions can overcome environmental problems but the economy and the energy consumption during grinding are still a matter of concern. Biodegradable and vegetable oils are considered eco-friendly oils, but they suffer from a lack of thermal stability which affects their ability of efficiently cooling. Using the cooling medium with the lowest amount can achieve the goal of the economy but it may be reflected negatively on the machinability. Furthermore, cryogenic lubrication doesn’t provide sufficient lubrication to reduce friction and hence energy consumption. The research described in the paper is such a comprehensive compilation of knowledge regarding the machinability and machining performance under different cooling and lubrication systems that it will aid the next generation of scientists in identifying current advancements as well as potential future directions of research on ecological aspects of machining for sustainability.
... Uhlman et al. [3] optimized the grinding wheel design for fute grinding processes by using the numerical analysis of complex contact conditions. Wasif et al. [4] used a fve-axis NC grinding process combined with contact conditions to generate a simplifed grinding wheel geometry for grinding end mills. Jianmin et al. [5] based on the principle of form grinding, combined with the meshing principle and the numerical method of piecewise accumulative chord length parameters, gave the basic calculation process of the profle of the form grinding wheel. ...
In the development of modern tools, the flute (or profiling flute) after design optimization is often obtained by grooving with a forming grinding wheel. At present, the main method of reverse forming wheel profile is the analytical method, which needs to solve the contact line equation according to the contact conditions. It is difficult to solve the equation. The solution value is unstable, which leads to the design error of the grinding wheel profile. In order to solve this problem, this paper proposes a new algorithm, called the pixel matrix method for short. This method is based on the spiral motion envelope method and mathematical morphology. First, the cross-section of the flute is discretized into a point cloud, and then, the envelope motion is carried out in the grinding wheel coordinate system. Second, the point cloud of the grinding wheel radial section is collected and converted into a binary image of pixel points. Finally, the profile of the binary image is extracted by erosion and dilation. The optimized profile of the formed grinding wheel reaches the accuracy requirements of the design and processing in the actual machining verification. This method can accurately reverse the profile of the forming grinding wheel. The calculation process is intuitive, avoiding the solution of the contact line equation, and the solution value is stable. It provides a new way to reverse the profile of the machining tool for cylindrical spiral products.
... These grinding processes are used to improve the low productivity rate of conventional grinding operations. However, high-performance grinding significantly changes the kinematic and thermal characteristics of the grinding process [4][5][6]. ...
The research presented in this study deals with the analysis, modeling, and optimization of thermal effects in the creep-feed grinding process. Advanced grinding technology is investigated, which is defined as an extreme production process accompanied by large amounts of interface thermal energy, which results in a heat-affected zone of the workpiece. An optimal control problem based on the conjugate gradient method was used. The optimal control approach simulated heat flux distribution in grinding for selected machining conditions based on the measured temperature inside the workpiece. A further goal of the control problem is to optimize the objective function to find the control variables for the desired process state. The optimization algorithm to minimize the objective function was conducted based on the critical heat flux parameters. Namely, by optimizing the relationship between the heating power and duration, the optimum grinding conditions are determined to achieve high productivity and quality. The solution of the gradient-based optimal control problem was obtained by the iterative numerical optimization technique. The results of the optimal heat control problem showed a good agreement with the experimental data.
... Hsieh et al. [7] established the mathematical model of drill helical groove and solved the free-form grinding wheel by contact theory. Wasif et al. [8] proposed an optimization algorithm for form grinding wheel profile based on a differential evolution algorithm. Shen et al. [9] studied a grinding wheel design method to design a wheel for grinding different small helical grooves on the existing helical rake faces of the tool. ...
Grinding wheel posture and geometric parameters are the key to optimizing the grinding process for helical grooves of solid end mills. However, the current envelope calculation models have not done enough research on the influence of the grinding wheel discretization method and grinding kinematics models mainly focus on helical grooves with constant core radius. Moreover, the matching error of the overall cross-section curve is ignored. These problems can reduce model generality, affect final calculation results, and cause inferior cutting performance. Therefore, a novel optimization algorithm for grinding wheel posture and geometric parameters is developed in this paper. Firstly, a parametric grinding wheel modeling method with adaptive adjustment of control variables is proposed, and a generalized grinding kinematics model for variable core radius is established. Then, by analyzing the sensitivity of cross-section parameters and the formation mechanism of the core radius, an iterative strategy based on parameter sets is established. Under the condition that the core radius is ensured in advance, the matching errors of rake angle, groove width, and overall cross-section curve are considered comprehensively to optimize the grinding wheel posture and geometric parameters. Finally, the proposed method is verified by simulation and machining. The results indicate that the proposed method can realize the envelope calculation of the helical groove with variable core radius, and optimize the grinding wheel posture and geometric parameters accurately and efficiently.
... Uhlmann et al. [17] presented a method for designing application-oriented grinding wheels to improve the productivity and the quality of grinding processes so that grinding wheels with different layers over its width were developed to compensate the varying and complex contact conditions. Wasif et al. [18] proposed an approach to determine the non-standard grinding wheel that can be economically produced or dressed to accurately grind the end-mill cutters using the five-axis CNC grinding process. ...
Groove is a key structure of high-performance integral cutting tools. It has to be manufactured by 5-axis grinding machine due to its complex spatial geometry and hard materials. The crucial manufacturing parameters (CMP) are grinding wheel positions and geometries. However, it is a challenging problem to solve the CMP for the designed groove. The traditional trial-and-error or analytical methods have defects such as time-consuming, limited-applying, and low accuracy. In this study, the problem is translated into a multiple output regression model of groove manufacture (MORGM) based on the big data technology and AI algorithms. The inputs are 34 groove geometry features, and the outputs are 5 CMP. Firstly, two groove machining big data sets with different range are established, each of which is includes 46,656 records. They are used as data resource for MORGM. Secondly, 7 AI algorithms, including linear regression, k nearest-neighbor regression, decision trees, random forest regression, support vector regression, and ANN algorithms, are discussed to build the model. Then, 28 experiments are carried out to test the big data set and algorithms. Finally, the best MORGM is built by ANN algorithm and the big data set with a larger range. The results show that CMP can be calculated accurately and conveniently by the built MORGM.
