Modeling of integral cutting tool grooves using envelope theory and numerical methods

• Guochao Li
• Honggen Zhou
• Xuwen Jing
• Guizhong Tian
• Lei Li
ORIGINAL ARTICLE

Abstract

A groove is a key component of the structure of end mills, drills, and other integrated cutting tools. Machining a groove is one of the most difficult, time-consuming, and costly manufacturing process; therefore, for the sake of reduction of the machining cost and meeting the environmental regulations, the modeling of a machined groove with known wheel geometry and position is necessary for cutting tool manufacture. In order to reveal the process more clear and precise, the envelope theory and numerical methods are used. First, the basic calculation procedure for groove section points is built using a meshing equation. Accordingly, four universal problems for the simulation of groove manufacturing process are analyzed by four typical examples. Namely, the wheel side surface may interfere the machined tool edge and lead to an incorrect simulation; the wheel revolution surface may overcut the machined tool edge and produce fake points that would disturb the results; the tip point might not be precise enough; and the groove section points might be distributed unevenly and result in an imprecise groove section. The conditions to solve these problems are established by mathematical formulas and calculated by numerical methods. In addition, an integral procedure is built to simulate the machined groove with correct, precise, and even distribution points. Finally, groove simulation software is developed using MATLAB GUI, and the results are verified.

Keywords

Cutting tool groove Manufacturing Numerical method

Notes

Funding information

This work was supported by the National Natural Science Foundation of China (No. 51605207) and the Natural Science Foundation of Jiangsu Province of China (No. BK20160563).

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© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

• Guochao Li
• 1
• 2
• Honggen Zhou
• 1
• 2
• Xuwen Jing
• 1
• 2
• Guizhong Tian
• 1
• 2
• Lei Li
• 1
• 2
1. 1.School of Mechanical EngineeringJiangsu University of Science and TechnologyZhenjiangChina
2. 2.Jiangsu Provincial Key Laboratory of Advanced Manufacturing for Marine Mechanical EquipmentJiangsu University of Science and TechnologyZhenjiangChina