Abstract: Applying circular-arc-projection method in flute grinding of cylindrical end-mills, methods of determining the position, the maximum allowable fillet radius, and the maximum allowable oblique angle of the grinding wheel are presented. The flute geometry is defined by cutting-edge curve, flute-width curve, and surface of revolution corresponding to core radius. The accuracy of rake angle is ensured by restraining the wheel position by conjugating the wheel surface with the cutting-edge curve. The surface of revolution corresponding to core radius and the flute-width curve are projected into the axial section of the wheel by using circular-arc-projection method. Equivalent machining errors of core radius and flute width are presented, and an optimization model for wheel-position determination is constructed to minimize the sum of squares of the equivalent machining errors and to ensure the accuracy of core radius and flute width. Contact fillet radius and contact oblique angle of the wheel are defined in the circular-arc-projection plane. Optimization models of fillet radius and oblique angle are constructed to maximize the contact fillet radius and contact oblique angle and to obtain the maximum allowable fillet radius and the maximum allowable oblique angle, which can provide a reference for selection of the geometric parameters of the wheel. The circular-arc-projection method adopt the equivalent machining errors to quantitatively evaluate the machining errors of core radius and flute width without determination of the cross-sectional profile of the flute in each iteration. Thus, the constructed models can be applied to various types of wheels and have high accuracy and short time consumption.

Key words: flute, grinding, wheel position, circular arc projection, helical groove