Abstract
Solid cutting tool is more and more widely used, such as aerospace, automobile and 3C. Helical groove is an important feature which influences the performance of solid cutting tool. Furthermore, groove grinding is the longest and largest material removal process in whole grinding of solid tool. Therefore, the most wear of grinding wheel occurs in its grinding. The worn wheel would result in groove grinding error without a proper compensation. The traditional compensation relies on the experience of machine operator, and generally, it is performed on site. In this paper, a compensation algorithm of worn wheel is proposed by analysing the boundary contact condition which is influenced by wheel wear. Furthermore, the algorithm is implemented by using C# and validated by a set of and experiments. The experimental results show that the ground tool flutes under compensation algorithm are controlled within designed tolerances; i.e., core radius errors are 1.7% and 0.7%, rake angle errors are 1.5% and 0.6%, and edge width errors are 4.3% and 5%.
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