Skip to main content
SpringerLink
Log in

Geometric modeling and grinder design for toroid-cone shaped cutters

  • Original Article
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

This paper presents a set of mathematical models for the design and manufacture of the helical flute and cutting-edge curve of a toroid-cone shaped revolving cutter. The study not only considers the section profile and relative feeding velocities of the grinding wheel used in the NC machining of the cutter, but also addresses the deviation of the cutting-edge curve, the residual material which exists between adjacent flutes, and the lack of cutter land. Through a process of numerical simulation, a compensation technique is developed which reduces the residual material and rebuilds the missing land. The accuracy of the theoretical models is verified by means of an experimental machining test using a WALTER CNC grinding machine. The experimental results are in good agreement with those predicted theoretically, thereby confirming the accuracy and reliability of the proposed models. This study serves as a valuable reference for researchers investigating the NC machining of cutters with special forms.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Rodin P (1977) Fundamentals of surface forming by cutting. Kiev, Vishta Shkola

  2. Rodin P (1966) Cutting tools. Graphical calculations and laboratory experiments, Kiev, Tehnika

  3. Belyaev S, Gordev B (1982) Automated calculation of disk tool profile for helical surfaces. J Stanki I Instr 6:53–57

    Google Scholar 

  4. Lio HX (1993) Smooth connecting of cutting edge curve on ball-end milling cutter. Tool Eng 2:10–12

    MathSciNet  Google Scholar 

  5. Tang YY, Chen CK, Wang S (1996) Geometry model and 2-axis NC machining of milling cutters with constant helical angle. J Harbin Inst Technol 28(5):5–7

    MATH  Google Scholar 

  6. Ya DC (1984) New manufacturing technology of conical type tool with helical groove. Tool Eng 1:1–10

    Google Scholar 

  7. Kang DC, Shiu S, Yau NS (1994) Calculation and measurement of cutting parameter of finger shape gear milling with helical groove. Tool Eng 5:15–20

    Google Scholar 

  8. Chang H, Ya DC (1997) General calculation on cutting edge of revolution tool with constant helical angle. Trans Ta-Lien Univ Technol 37(1):63–67

    Google Scholar 

  9. Hauran L (1995) Study on smooth connecting of edge curve of ball end mill. Tool Eng 29(2):11–13

    Google Scholar 

  10. Kung CH, Pin HC (1994) Broad definition and applications of helical angle. Mech Eng 1:14–15

    Google Scholar 

  11. Lio HX (1997) The forming theory and structure of edge line on revolution file with sideways knife. Tool Eng 31(2):15–16

    Google Scholar 

  12. Lio CM (1989) Calculation assistant design on molding milling cutter of end milling groove. Tool Eng 1:6–9

    Google Scholar 

  13. Lee YH, Tung YW (1987) Optimum design of cross section of end milling—a orthogonal test method. Tool Eng 11:36–38

    Google Scholar 

  14. Li LF (1995) Calculating the normal section of helical groove of milling cutter by computer. Tool Eng 5:15–19

    Google Scholar 

  15. Wu XT (1983) Machining theory of toroid-cone helical surface and it’s application. Technique Report, ChiaoTung University, His-An

  16. Lo I (1995) Machining of cone milling using CNC machine. Tool Eng 12:14–16

    Google Scholar 

  17. Jou CH, Shen C, Wang M (1995) Study on the mathematical model of machining non-conventional form millers by NC methods. J Southeast Univ 25(2):25–29

    MathSciNet  Google Scholar 

  18. Kung CH, Pin HC (1997) CNC grinding method of trace on cutting point and it’s application on toroid-cone shaped cutters. Tool Eng 31(9):19–24,

    Google Scholar 

  19. Tai CC, Fuh KH (1995) Model for cutting forces prediction in ball-end milling. Int J Mach Tools Manuf 35(4):511–524

    Article  Google Scholar 

  20. Lee P, Altintas Y (1996) Prediction of ball-end milling forces from orthogonal cutting data. Int J Mach Tools Manuf 36(9):1059–1063

    Article  Google Scholar 

  21. Yang M, Heeduck P (1991) The prediction of cutting force in ball-end milling. Int J Mach Tools Manuf 31(1):45–54

    Article  Google Scholar 

  22. Yucesan G, Altintas Y (1996) Prediction of ball end milling forces. J Eng Ind 118(2):95–103

    Google Scholar 

  23. Sheth DS (1988) CAD software for geometry and process analysis of helical machining. Dissertation, University of Massachusetts

  24. Altintas Y, Lee P (1996) A general mechanics and dynamics model for helical end mills. Ann CIRP 45(1):59–63

    Google Scholar 

  25. Mannan MA, Lindstrom B (1986) Performance for end mills made of different tool materials with regards to tool life and stability. Ann CIRP 35(1):37–44

    Google Scholar 

  26. Kops L, Vo DT (1990) Determination of the equivalent diameter of an end mill based on its compliance. Ann CIRP 39(1):93–96

    Article  Google Scholar 

  27. Kang SK, Ehmann KF, Lin C (1997) A CAD approach to helical groove machining: numerical evaluation and sensitivity analysis. Int J Mach Tools Manuf 37(1):101–117

    Article  Google Scholar 

  28. Lio CY, Lio HM (1997) Mathematical model of helical groove on toroid-cone shaped cutters. Tool Eng 34:3–6

    Google Scholar 

  29. Kang SK, Ehmann KF, Lin C (1996) A CAD approach to helical flute machining-I. Mathematical model and model solution. Int J Mach Tools Manuf 36(1):141-153

    Article  Google Scholar 

  30. Jou CH, Ya DC, Wu XT (1991) The forming theory of special revolution tools of plane type rake face. Tool Eng 25(5):17-21

    Google Scholar 

  31. Chang JC, Shen P, Wang HC, Wu HT (1998) Machining sculptured surfaces by second order curvature cuttering. Chin J Mech Eng 34(2):87–92

    Google Scholar 

  32. Bedi S, Gravelle S, Chen YH (1997) Principal curvature alignment technique for machining complex surfaces. J Manuf Sci Eng Trans ASME 119:756–765

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Cheng Shiu University, Kaohsiung, Taiwan, 83342

    Jone-Ming Hsieh & Ying-Chien Tsai

Authors
  1. Jone-Ming Hsieh
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Ying-Chien Tsai
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Jone-Ming Hsieh.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Hsieh, JM., Tsai, YC. Geometric modeling and grinder design for toroid-cone shaped cutters. Int J Adv Manuf Technol 29, 912–921 (2006). https://doi.org/10.1007/s00170-005-2613-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-005-2613-1

Keywords

Search

Navigation