Modeling and numerical simulation for the machining of helical surface profiles on cutting tools |
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Authors: | Yuwen Sun Jun Wang Dongming Guo Qiang Zhang |
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Affiliation: | (1) School of Mechanical Engineering, Dalian University of Technology, Dalian, 116024, People’s Republic of China;(2) School of Mechanical and Manufacturing Engineering, The University of New South Wales, Sydney, NSW, 2052, Australia |
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Abstract: | The classical conjugation and envelope method is very accurate and effective for forward and inverse calculations of grinding
helical surfaces. However, this method involves complicated mathematics and requires that the profiles be continuous. It can
also result in undercutting or interference to the desired surface profiles. In this paper, a new approach is proposed to
simulate the grinding process of helical surfaces on cutting tools. The paper begins with the reconstruction of cutter helicoids
from sampled points. Using the recovered helical parameters from the sample points, the cross-sectional profile of the cutter
surface is derived using a polynomial curve. A numerical method for calculating the profile of the grinding wheel required
for the cutter surface profile is then provided. Finally, an optimization method is presented for solving the problem of inverse
calculation to determine the helical surface profile for a given grinding wheel profile and setting parameters. The feasibility
of the approach is tested by simulation results, which shows that the proposed approach can eliminate undesired tool-work
interferences and undercutting. |
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Keywords: | Helical surface Profiling Numerical simulation Grinding Modeling |
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