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Calculation of wheel path for 3+2-axis grinding of brazed carbide profile mill cutters for wood and plastic

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Abstract

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.

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Acknowledgements

Research work was realized in the Mechanical Engineering Laboratory of The Academy of Applied Technical Studies Belgrade - Department of Traffic, Mechanical and Safety Engineering, and the machine tools laboratory of the Mechanical Engineering faculty in Belgrade - Department for Production Engineering.

Funding

The presented research was supported by the Ministry of Education, Science and Technological Development of the Republic of Serbia through the project: “Integrated research in macro, micro, and nano mechanical engineering” (contract no. 451-03-47/2023-01/200105 dated 3 February 2023).

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Author notes

  1. Goran Vasilic, Sasa Zivanovic, Zoran Dimic, Branko Kokotovic, and Nikola Slavkovic contributed equally to this work.

Authors and Affiliations

  1. Department of traffic, mechanical and safety engeneering, The Academy of Applied Technical Studies, Katarine Ambrozic 3, Belgrade, 11000, Serbia

    Milan Milutinovic & Goran Vasilic

  2. Department for production engineering, Faculty of mechanical engineering, University of Belgrade, Kraljice Marije 16, Belgrade, 11120, Serbia

    Sasa Zivanovic, Branko Kokotovic & Nikola Slavkovic

  3. Robotics department, Research and Development Institute Lola, Kneza Viseslava 70A, Belgrade, 11030, Serbia

    Zoran Dimic

Authors
  1. Milan Milutinovic
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  2. Goran Vasilic
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  3. Sasa Zivanovic
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  4. Zoran Dimic
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  5. Branko Kokotovic
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  6. Nikola Slavkovic
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Contributions

MM: development of the concept of a CNC 3-axis grinding machine with a rotary table and indexing head. Kinematic model of the machine. Production of machine parts and assembly of the machine. Manufacturing of profile mill cutters on developed CNC machine. GV: machining strategies, preparation of programs for CNC machine, adjustment of the equipment, manufacturing of profile mill cutters on developed CNC machine. SZ: development and design of a CNC 3-axis grinding machine. ZD: development of a control and programming system based on the LinuxCNC platform. BK: development and design of a CNC 3-axis grinding machine. NS: development of a Matlab program for profile discretization and determination of profile point coordinates.

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Correspondence to Milan Milutinovic or Goran Vasilic.

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Milutinovic, M., Vasilic, G., Zivanovic, S. et al. Calculation of wheel path for 3+2-axis grinding of brazed carbide profile mill cutters for wood and plastic. Int J Adv Manuf Technol 130, 4603–4620 (2024). https://doi.org/10.1007/s00170-024-12992-3

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