An Approach on Wheel Setup Calculation for Helical Rake Flank Sharpening of Broaching Tool

doi:10.3901/JME.2019.11.205

Abstract

Abstract: Helical gullets are important structure of the helical broaching tools, and the precision and high-quality sharpening for the corresponding rake flanks is significant to the work performance and the life of the broaching tools. Therefore, a wheel setup method for the helical rake flank sharpening is proposed. Firstly, the wheel setup model and the motion matrix are established. Next, a discrete spatial wheel swept volume based machined gullet axial section profile identification method is presented, as well as the tracing of the discrete contact curve. On this foundation, the grinding processes of helical rake flank are analyzed and the constraints conditions are summarized, the wheel orientation calculation model for the helical rake flank is given as well as the optimized search solving method. At last, examples are performed by proposed method, and its effectiveness is verified by the precision comparison with analytical method results and the distribution status of contact curve. Moreover, the analyses of the relationship among wheel orientation, wheel radius and width of machined gullet is taken, and optimal selection of wheel setup is suggested.

Key words: contact curve, grinding constraints, helical gullet, orientation optimal, transverse profile, wheel orientation solving

CLC Number:

TH132

JIA Kang, HONG Jun, ZHANG Yinhang. An Approach on Wheel Setup Calculation for Helical Rake Flank Sharpening of Broaching Tool[J]. Journal of Mechanical Engineering, 2019, 55(11): 205-214.

References

[1] 袁哲俊,刘华明. 金属切削刀具设计手册(单行本):拉刀[M]. 北京:机械工业出版社,2009. YUAN Zhejun,LIU Huaming. Design manual of metal cutting tool:Broach[M]. Beijing:China Machine Press,2009.
[2] KANG S K,EHMANN K F,LIN C. A CAD approach to helical groove machining-I. mathematical model and model solution[J]. International Journal of Machine Tools and Manufacture,1996,36(1):141-153.
[3] REN B Y,TANG Y Y,CHEN C K. The general geometrical models of the design and 2-axis NC machining of a helical end-mill with constant pitch[J]. Journal of Materials Processing Technology,2001,115(3):265-270.
[4] CHEN F,BIN H. A novel CNC grinding method for the rake face of a taper ball-end mill with a CBN spherical grinding wheel[J]. The International Journal of Advanced Manufacturing Technology,2008,41(9-10):846-857.
[5] ZHANG W,WANG X,HE F,et al. A practical method of modelling and simulation for drill fluting[J]. International Journal of Machine Tools and Manufacture,2006,46(6):667-672.
[6] EHMANN K F,DEVRIES M F. Grinding wheel profile definition for the manufacture of drill flutes[J]. CIRP Annals-Manufacturing Technology,1990,39(1):153-156.
[7] KALDOR S,RAFAEL A M,MESSINGER D. On the CAD of profiles for cutters and helical flutes-geometrical aspects[J]. CIRP Annals-Manufacturing Technology,1988,37(1):53-56.
[8] KO SL. Geometrical analysis of helical flute grinding and application to end mill[J]. Transaction of NAMRI/SME,1994,22(1):165-172.
[9] 吴序堂. 齿轮啮合原理[M]. 北京:机械工业出版社,1982. WU Xutang. Theory of gear[M]. Beijing:China Machine Press,1982.
[10] KANG S K,EHMANN K F,LIN C. A CAD approach to helical groove machining. Part 2:Numerical evaluation and sensitivity analysis[J]. International Journal of Machine Tools and Manufacture,1997,37(1):101-117.
[11] SHI Z,MALKIN S. Valid machine tool setup for helical groove machining[J]. Journal of Manufacturing Processes,2004,6(2):148-154.
[12] KARPUSCHEWSKI B,JANDECKA K,MOUREK D. Automatic search for wheel position in flute grinding of cutting tools[J]. CIRP Annals-Manufacturing Technology,2011,60(1):347-350.
[13] REN L,WANG S,YI L,et al. An accurate method for five-axis flute grinding in cylindrical end-mills using standard 1V1/1A1 grinding wheels[J]. Precision Engineering,2016,43:387-394.
[14] WU C T,CHEN C K. Manufacturing models for the design and NC grinding of a revolving tool with a circular arc generatrix[J]. Journal of Materials Processing Tech.,2001,116(2-3):114-123.
[15] XIAO S,WANG L,CHEN ZC,et al. A new and accurate mathematical model for computer numerically controlled programming of 4Y1 wheels in 2½-axis flute grinding of cylindrical end-mills[J]. Journal of Manufacturing Science and Engineering,2013,135(4):041008-1-041008-11.
[16] FRIEDMAN M Y,BOLESLAVSKI M,MEISTER I. The profile of a helical slot machined by a disc-type cutter with an infinitesimal width,considering undercutting[C]//Proceedings of the Thirteenth International Machine Tool Design and Research Conference. Macmillan Education UK:London,1973:245-246.
[17] LI G,SUN J,LI J. Modeling and analysis of helical groove grinding in end mill machining[J]. J. Mater. Process. Technol.,2014,214:3067-3076.
[18] JIA K,HONG J,ZHENG S,et al. An approach on wheel position and orientation calculation for helical broaching tool sharpening[J]. International Journal of Advanced Manufacturing Technology,2017,92(5-8):1991-2000.
[19] 贾康,洪军,万少可,等. 拉刀螺旋前刀面刃磨砂轮安装姿态计算方法[J]. 西安交通大学学报,2017,51(2):121-127. JIA Kang,HONG Jun,WAN Shaoke,et al. Wheel orientation calculation for helical rake flank sharpening of broaching tool[J]. Journal of Xi'an Jiaotong University,2017,51(2):121-127.
[20] KIM J H,PARK J W,KO T J. End mill design and machining via cutting simulation[J]. Computer-Aided Design,2008,40(3):324-333.
[21] 奚威. 设计螺旋槽成型铣刀的CAD方法[J]. 工具技术,1995(12):11-13. XI Wei. CAD method for designing spiral groove milling cutter[J]. Tool Engineering,1995(12):11-13.
[22] IVANOV V,NANKOV G,KIROV V. CAD orientated mathematical model for determination of profile helical surfaces[J]. International Journal of Machine Tools and Manufacture,1998,38(8):1001-1015.