Skip to main content
SpringerLink
Log in

Technological preparation of thread milling cutter production at the design stage

  • Technical Paper
  • Published:
Journal of the Brazilian Society of Mechanical Sciences and Engineering Aims and scope Submit manuscript

Abstract

This research was performed on the technological feasibility of manufacturing the multiple thread milling cutter flutes based on their mathematical and experimental simulation and studying the possibility of manufacturing a prototype thread milling cutter with the use of grinding wheels of typical profiles. Using the Walter Basic kinematic scheme as an example, a system of mathematical expressions was developed to determine the flute end section profile produced by a grinding wheel, taking into account the kinematic scheme of the multi-axis CNC tool grinding machines. Proposed mathematical expressions were approved by experimental studies when machining helical flutes on caprolon workpieces with a diameter of 34.5 mm with the use of a universal grinding machine. The comparison of the fluting profiles in the end section (both experimental and calculated) showed satisfactory convergence; the errors (up to 0.42 mm) could be explained by inaccuracies in grinding wheel installation, workpiece yielding, errors in the experiment parameter settings and increasing discrepancies in the error measurement direction to the core diameter. To study the technological feasibility of the flutes of the thread milling cutter, the CoroMill Plura R217.15-140100AC26N thread milling cutter was chosen as a prototype. The end section of the tool was obtained by passing a plane through the top of the tooth, and installation parameters for the grinding wheel type 1V1 (conical profile) were assigned using a developed mathematical expression system. It was established that the grinding wheel type 1V1 made it possible to assign the installation parameters required in the fluting of the prototype. The possibility of choosing the grinding wheel profile and geometric parameters as well as its installation parameters based on the manufacturing simulation of the prototype performed in Walter Helitronic Tool Studio was confirmed, which makes it possible to perform thread milling cutter production technological preparation using the developed mathematical expressions.

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

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9

Similar content being viewed by others

Availability of data and materials

All data generated or analyzed during this study are included in this published article.

References

  1. Gao H, Lu S, Yang A, Bao Y (2017) A methodology for helical mill-grinding of tiny internal threads made of hard brittle materials. Int J Adv Manuf Technol 91(1–4):25–37. https://doi.org/10.1007/s00170-016-9727-5

    Article  Google Scholar 

  2. Evsyukov SA, Nebogov SM, Punin VI, Fedotov IL (2016) Surface plastic deformation of threads in ultrasound treatment. Russ Eng Res 36(8):620–625. https://doi.org/10.3103/S1068798X16080086

    Article  Google Scholar 

  3. Evsyukov S, Nebogov S, Fedotov I (2016) Pipe thread wear-resistant ultrasonic hardening unit. Vibroengineering PROCEDIA 8:142–146

    Google Scholar 

  4. Morgunov VA, Nebogov SM, Fedotov IL (2018) Elevation of the wear resistance of threads of tubing strings under the action of ultrasound. Metallurgist 61(11–12):1108–1114. https://doi.org/10.1007/s11015-018-0613-2

    Article  Google Scholar 

  5. Fedorova LV, Fedorov SK, Ivanova YS, Voronina MV (2017) Increase of wear resistance of the drill pipe thread connection by electromechanical surface hardening. Int J Appl Eng Res 12(18):7485–7489

    Google Scholar 

  6. Zubkov NN (2020) Novel method of single-pass threading by cutter. In: Radionov AA, Kravchenko OA, Guzeev VL, Rozhdestvenskiv YV (eds) Proceedings of the 5th international conference on industrial engineering (ICIE 2019) volume II. Springer, pp 973–982. https://doi.org/10.1007/978-3-030-22063-1_103

    Chapter  Google Scholar 

  7. Fromentin G, Poulachon G (2010) Geometrical analysis of thread milling—part 1: evaluation of tool angles. Int J Adv Manuf Technol 49(1–4):73–80. https://doi.org/10.1007/s00170-009-2402-3

    Article  Google Scholar 

  8. Fromentin G, Poulachon G (2010) Geometrical analysis of thread milling—part 2: calculation of uncut chip thickness. Int J Adv Manuf Technol 49(1–4):81–87. https://doi.org/10.1007/s00170-009-2401-4

    Article  Google Scholar 

  9. Glushko EV (2008) Thread milling by the engagement method. Russ Eng Res 28(7):720–722. https://doi.org/10.3103/S1068798X08070204

    Article  Google Scholar 

  10. Danilenko BD (2015) Cutting conditions for thread mills. Russ Eng Res 35(1):76–77. https://doi.org/10.3103/S1068798X15010098

    Article  Google Scholar 

  11. Kirichek AV, Afonin AN (2007) Stress-strain state of the thread-milling tool and blank. Russ Eng Res 27(10):715–718. https://doi.org/10.3103/S1068798X07100152

    Article  Google Scholar 

  12. Kosarev VA, Grechishnikov VA, Kosarev DV (2009) Milling internal thread with planetary tool motion. Russ Eng Res 29(11):1177–1179. https://doi.org/10.3103/S1068798X09110227

    Article  Google Scholar 

  13. Lee SW, Nestler A (2012) Simulation-aided design of thread milling cutter. Procedia CIRP 1:120–125. https://doi.org/10.1016/j.procir.2012.04.019

    Article  Google Scholar 

  14. Lee SW, Kasten A, Nestler A (2013) Analytic mechanistic cutting force model for thread milling operations. Procedia CIRP 8:546–551. https://doi.org/10.1016/j.procir.2013.06.148

    Article  Google Scholar 

  15. Mal’kov OV (2013) Precision of the external-thread profile in thread cutting. Russ Eng Res 33(3):172–175. https://doi.org/10.3103/S1068798X1303012X

    Article  Google Scholar 

  16. Wan M, Altintas Y (2014) Mechanics and dynamics of thread milling process. Int J Mach Tools Manuf 87:16–26. https://doi.org/10.1016/j.ijmachtools.2014.07.006

    Article  Google Scholar 

  17. Zhao XF, Shi HY, He L (2016) The influence of the grinding wheel parameters on the spiral groove parameters of the end mill. Mater Sci Forum 836–837:139–146. https://doi.org/10.4028/www.scientific.net/MSF.836-837.139

    Article  Google Scholar 

  18. Zhao XF, Shi HY, He L (2014) The mathematic model of end Mill’s rake face based on the fillet and two attitude angles of grinding wheel. Mater Sci Forum 800–801:249–253. https://doi.org/10.4028/www.scientific.net/MSF.800-801.249

    Article  Google Scholar 

  19. Xiao S, Wang L, Chen ZC, Shequan W, Tan A (2013) A new and accurate mathematical model for computer numerically controlled programming of 4Y1 wheels in 2½-axis flute grinding of cylindrical end-mills. J Manuf Sci Eng 135(4):e041008. https://doi.org/10.1115/1.4023379

    Article  Google Scholar 

  20. Zhidyaev AN (2018) Impact of grinding wheel position on flute profile of end mill and cutting process. IOP Conf Ser Mater Sci Eng. https://doi.org/10.1088/1757-899X/302/1/012069

    Article  Google Scholar 

  21. Li G, Sun J, Li J (2014) Modeling and analysis of helical groove grinding in end mill machining. J Mater Process Technol 214(12):3067–3076. https://doi.org/10.1016/j.jmatprotec.2014.07.009

    Article  Google Scholar 

  22. Kim JH, Park JW, Ko TJ (2008) End mill design and machining via cutting simulation. Comput Aided Des 40(3):324–333. https://doi.org/10.1016/j.cad.2007.11.005

    Article  Google Scholar 

  23. Chen Z, Ji W, He G, Liu X, Wang L, Rong Y (2018) Iteration based calculation of position and orientation of grinding wheel for solid cutting tool flute grinding. J Manuf Process 36:209–215. https://doi.org/10.1016/j.jmapro.2018.10.012

    Article  Google Scholar 

  24. Karpuschewski B, Jandecka K, Mourek D (2011) Automatic search for wheel position in flute grinding of cutting tools. CIRP Ann 60(1):347–350. https://doi.org/10.1016/j.cirp.2011.03.113

    Article  Google Scholar 

  25. Li G, Zhou H, Jing Z, Tian G, Li L (2017) An intelligent wheel position searching algorithm for cutting tool grooves with diverse machining precision requirements. Int J Mach Tools Manuf 122:149–160. https://doi.org/10.1016/j.ijmachtools.2017.07.003

    Article  Google Scholar 

  26. Petukhov YE, Movsesyan AV (2007) Determining the shape of the back surface of disc milling cutter for machining a contoured surface. Russ Eng Res 27(8):519–521. https://doi.org/10.3103/S1068798X07080084

    Article  Google Scholar 

  27. Shi Z, Malkin S (2004) Valid machine tool setup for helical groove machining. J Manuf Process 6(2):148–154. https://doi.org/10.1016/S1526-6125(04)70069-9

    Article  Google Scholar 

  28. Kaldor S, Rafael AM, Messinger D (1988) On the CAD of profiles for cutters and helical flutes - geometrical aspects. CIRP Ann 37(1):53–56. https://doi.org/10.1016/S0007-8506(07)61584-4

    Article  Google Scholar 

  29. Kang D, Armarego E (2003) Computer aided geometrical analysis of the fluting operation for twist drill design and production. I. Forward analysis and generated flute profile. Mach Sci Technol Int J 7(2):221–248. https://doi.org/10.1081/MST-120022779

    Article  Google Scholar 

  30. Kang SK, Ehmann KF, Lin C (1996) A CAD approach to helical groove machining—I. Mathematical model and model solution. Int J Mach Tools Manuf 36(1):141–153. https://doi.org/10.1016/0890-6955(95)92631-8

    Article  Google Scholar 

  31. Balandin AD, Danilenko BD (2013) Producing helical channels on taps by means of face mills. Russ Eng Res 33(6):355–357. https://doi.org/10.3103/S1068798X1306004X

    Article  Google Scholar 

  32. Danilenko BD, Malevskii NP (2009) Forming a helical chip-channel surface in a spiral drill by specifying two generative straight lines. Russ Eng Res 29(4):397–399. https://doi.org/10.3103/S1068798X09040157

    Article  Google Scholar 

  33. Ivanov VK, Nankov G (1998) Profiling of rotation tools for forming of helical surfaces. Int J Mach Tools Manuf 38(9):1125–1148. https://doi.org/10.1016/S0890-6955(98)00003-0

    Article  Google Scholar 

  34. Li G, Zhou H, Jing X, Tian G, Li L (2018) Modeling of integral cutting tool grooves using envelope theory and numerical methods. Int J Adv Manuf Technol 98(1–4):579–591. https://doi.org/10.1007/s00170-018-2181-9

    Article  Google Scholar 

  35. Nhuyen VH, Ko S (2013) Determination of workpiece profile and influence of singular point in helical grooving. CIRP Ann 62(1):323–326. https://doi.org/10.1016/j.cirp.2013.03.009

    Article  Google Scholar 

  36. Zhang SY, Liang ZQ, Wang XB, Zhou TF, Jiao L, Yan P (2016) Influence of wheel position parameters on flute profile of micro-drill. Mater Sci Forum 874:52–58. https://doi.org/10.4028/www.scientific.net/MSF.874.52

    Article  Google Scholar 

  37. Zhang W, Wang Z, He F, Ziong D (2006) A practical method of modelling and simulation for drill fluting. Int J Mach Tools Manuf 46(6):667–672. https://doi.org/10.1016/j.ijmachtools.2005.07.007

    Article  Google Scholar 

  38. Malkova LD (2019) Surface modeling as a tool for visualization and analysis of machining problems. AIP Conf Proc 2195(1):020056. https://doi.org/10.1063/1.5140156

    Article  Google Scholar 

  39. Balandin AD, Danilenko BD (2008) Margin in sharpening helical channels of tool. Russ Eng Res 28(8):814–815. https://doi.org/10.3103/S1068798X08080200

    Article  Google Scholar 

  40. Ehrmann KF, DeVries MF (1990) Grinding wheel profile definition for the manufacture of drill flutes. CIRP Ann 39(1):153–156. https://doi.org/10.1016/S0007-8506(07)61024-5

    Article  Google Scholar 

  41. Malkov OV, Pavlyuchenkov IA (2020) Thread milling cutter flute production possibility research by using typical profiles grinding wheels. In: Radionov AA, Kravchenko OA, Guzeev VI, Rozhdestvenskiy YV (eds) Proceedings of the 5th international conference on industrial engineering (ICIE 2019) volume II. Springer International Publishing, London, pp 1089–1096

    Chapter  Google Scholar 

  42. Guochao L (2017) A new algorithm to solve the grinding wheel profile for end mill groove machining. Int J Adv Manuf Technol 90(1–4):775–784. https://doi.org/10.1007/s00170-016-9408-4

    Article  Google Scholar 

  43. Rababah MM, Chen ZC (2013) An automated and accurate CNC programming approach to five-axis flute grinding of cylindrical end-mills using the direct method. J Manuf Sci Eng 135(1):e011011. https://doi.org/10.1115/1.4023271

    Article  Google Scholar 

  44. Wang L, Kong L, Jianfeng L, Chen ZC (2017) A parametric and accurate CAD model of flat end mills based on its grinding operations. Int J Precis Eng Manuf 18(10):1363–1370. https://doi.org/10.1007/s12541-017-0162-9

    Article  Google Scholar 

  45. Beju LD, Brîndaşu DP, Muţiu NC, Rothmund J (2016) Modeling, simulation and manufacturing of drill flutes. Int J Adv Manuf Technol 83(9–12):2111–2127. https://doi.org/10.1007/s00170-015-7710-1

    Article  Google Scholar 

  46. Zhao XF, He L, Shi HY (2013) Research on the mathematical model of helical groove of the end mill based on the grinding wheel attitude. Key Eng Mater 589–590:416–420. https://doi.org/10.4028/www.scientific.net/KEM.589-590.416

    Article  Google Scholar 

  47. Ivanov V, Nankov G, Kirov V (1998) CAD orientated mathematical model for determination of profile helical surfaces. Int J Mach Tools Manuf 38(8):1001–1015. https://doi.org/10.1016/S0890-6955(98)00002-9

    Article  Google Scholar 

  48. Wang L, Chen ZC, Jianfeng L, Sun J (2016) A novel approach to determination of wheel position and orientation for five-axis CNC flute grinding of end mills. Int J Adv Manuf Technol 84(9–12):2499–2514. https://doi.org/10.1007/s00170-015-7851-2

    Article  Google Scholar 

  49. Voronov SA, Kiselev IA (2018) Influence of technological system’s rigidity on the dynamics of grinding process of flexible parts. MATEC Web Conf 226:02002. https://doi.org/10.1051/matecconf/201822602002

    Article  Google Scholar 

  50. Voronov SA, Veidun M (2017) Mathematical modeling of the cylindrical grinding process. J Mach Manuf Reliab 46(4):394–403. https://doi.org/10.3103/S1052618817030177

    Article  Google Scholar 

  51. Pavlyuchenkov IA, Malkov OV (2018) Certificate of state registration of computer software No. 2018661176, Russian Federation. Solid end thread milling cutter flute profiling. Rightsholders: Pavlyuchenkov I.A., Malkov O.V. Application No. 2018616913; date of application receipt: 04.07.2018; date of registration: 04.09.2018; date of publication: 04.09.2018. Bul. No. 9. – 1 p

Download references

Acknowledgements

Not applicable.

Funding

This study received no specific funding from public, commercial or not-for-profit funding agencies.

Author information

Authors and Affiliations

  1. Tool and Tooling Technology Department, Bauman Moscow State Technical University, Building 1, 5 Vtoraya Baumanskaya St., Moscow, Russian Federation, 105005

    O. Malkov & I. Pavlyuchenkov

Authors
  1. O. Malkov
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. I. Pavlyuchenkov
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

OM developed the research, was a major contributor in writing the manuscript and prepared the references section. IP collected, analyzed and interpreted data, and created figures and tables.

Corresponding author

Correspondence to I. Pavlyuchenkov.

Ethics declarations

Conflict of interest

The authors declare that they have no competing interests.

Additional information

Technical Editor: Lincoln Cardoso Brandao.

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Malkov, O., Pavlyuchenkov, I. Technological preparation of thread milling cutter production at the design stage. J Braz. Soc. Mech. Sci. Eng. 45, 413 (2023). https://doi.org/10.1007/s40430-023-04336-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s40430-023-04336-1

Keywords

Search

Navigation