Abstract
Groove is one of the key structures of end mills. Some of them could be machined by standard grinding wheels (1A1 or 1V1 type), some others must design new wheel profiles. Based on the enveloping and analytic geometry theories, a novel algorithm was proposed to calculate the wheel profiles for special groove machining. The machining process was analyzed, the contact line principles were discussed, and the calculation procedure was detailed. In addition, the algorithm was implemented on a personal computer by using the MATLAB programming language. Therefore, the desired wheel profile could be computed automatically with four input parameters, namely, the groove lead, the wheel axial vector, the point coordinates on the wheel axis, and the discrete points on the groove profile (or groove profile expression). The proposed algorithm and the corresponding program were finally verified by three different examples. The results demonstrated good agreements with the practical wheel profiles.
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