Skip to main content
SpringerLink
Log in

Process modeling of end mill groove machining based on Boolean method

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Helical groove is one of the key structures of end mills. Its grinding process is the hardest and most time-consuming in end mill machining. According to the practical groove-grinding process, a Boolean method to simulate the groove-grinding process is proposed in this paper. The groove model is obtained with the known wheel geometry by a sequence of Boolean operations. Accordingly, the wheel used to machine a desired groove is deduced with the similar method. Based on the Boolean operation results and principles of differential geometry, contact lines of the wheel and groove are illustrated and calculated to optimize the groove-grinding process. Wheel positions relative to the blank are described by a sequence of mathematical coordinates. Wheel profile expressions are built with the corresponding transformation matrixes including groove geometry transformation matrix, cutter tip transformation matrix, and start processing position transformation matrix. Some simulated examples are included to illustrate the presented method.

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. Ehmanna KF, Devries MF (1990) Grinding wheel profile definition for the manufacture of drill flutes. CIRP Ann Manuf Technol 39:153–156

    Article  Google Scholar 

  2. Kang SK, Ehmann KF, Lin C (1997) A CAD approach to helical groove machining. Part 2: numerical evaluation and sensitivity analysis. Int J Mach Tools Manuf 37:101–117

    Article  Google Scholar 

  3. Wang LM, Chen ZC (2014) A new CAD/CAM/CAE integration approach to predicting tool deflection of end mills. Int J Adv Manuf Technol 72(9–12):1677–1686

    Article  Google Scholar 

  4. Berbinschi S, Teodor VG, Oancea N (2012) 3D graphical method for profiling tools that generate helical surfaces. Int J Adv Manuf Technol 60:505–512

    Article  Google Scholar 

  5. Berbinschi S, Teodor V, Oancea N (2012) A study on helical surface generated by the primary peripheral surfaces of ring tool. Int J Adv Manuf Technol 61:15–24

    Article  Google Scholar 

  6. Teodor VG, Popa I, Oancea N (2010) The profiling of end mill and planing tools to generate helical surfaces known by sampled points. Int J Adv Manuf Technol 51:439–452

    Article  Google Scholar 

  7. Kaldor S, Rafael AM, Messinger D (1988) On the CAD of profiles for cutters and helical flutes-geometrical aspects. CIRP Ann Manuf Technol 37:53–56

    Article  Google Scholar 

  8. Pham TP, Ko SL (2010) A manufacturing model of an end mill using a five -axis CNC grinding machine. Int J Adv Manuf Technol 48:461–472

    Article  Google Scholar 

  9. Ko SL (1994) Geometrical analysis of helical flute grinding and application to end mill. Trans NAMRI/SME 22:165–172

    Google Scholar 

  10. Lin SW, Lai HY (2001) A mathematical model for manufacturing ball-end cutters using a two-axis NC machine. Int J Adv Manuf Technol 17:881–888

    Article  Google Scholar 

  11. Lin SW (2001) Study on the 2-axis NC machining of a toroid-shaped cutter with a constant angle between the cutting edge and the cutter axis. J Mater Process Technol 115(3):338–343

    Article  Google Scholar 

  12. Chen WF, Lai HY, Chen CK (2001) A precision tool model for concave cone-end milling cutters. Int J Adv Manuf Technol 18:567–578

    Article  Google Scholar 

  13. Chen JY, Lee BY, Chen CH (2008) Planning and analysis of grinding processes for end mills of cemented tungsten carbide. J Mater Process Technol 201:618–622

    Article  Google Scholar 

  14. Puig A, Perez VL, Tost D (2003) 3D simulation of tool machining. Comput Graph 27(1):99–106

    Article  Google Scholar 

  15. Tost D, Puig A, Perez VL (2004) Boolean operations for 3D simulation of CNC machining of drilling tools. Comput Aided Des 36(4):315–323

    Article  Google Scholar 

  16. Mohan LV, Shunmugam MS (2004) CAD approach for simulation of generation machining and identification of contact lines. Int J Mach Tools Manuf 44:717–723

    Article  Google Scholar 

  17. Kim JH, Park JW, Ko TJ (2008) End mill design and machining via cutting simulation. Comput Aided Des 40:324–333

    Article  Google Scholar 

  18. Tandon P, Rajik KM (2009) Three dimensional modeling and finite element simulation of a generic end mill. Comput Aided Des 41(2):106–114

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Key Laboratory of High Efficiency and Clean Mechanical Manufacture of MOE, School of Mechanical Engineering, Shandong University, Jinan, 250061, China

    Guochao Li, Jie Sun & Jianfeng Li

Authors
  1. Guochao Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Jie Sun
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jianfeng Li
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Jie Sun.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Li, G., Sun, J. & Li, J. Process modeling of end mill groove machining based on Boolean method. Int J Adv Manuf Technol 75, 959–966 (2014). https://doi.org/10.1007/s00170-014-6187-7

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-014-6187-7

Keywords

Search

Navigation