An iterative optimization algorithm for posture and geometric parameters of grinding wheel based on cross-section sensitivity and matching constraints of solid end mills

Abstract

Grinding wheel posture and geometric parameters are the key to optimizing the grinding process for helical grooves of solid end mills. However, the current envelope calculation models have not done enough research on the influence of the grinding wheel discretization method and grinding kinematics models mainly focus on helical grooves with constant core radius. Moreover, the matching error of the overall cross-section curve is ignored. These problems can reduce model generality, affect final calculation results, and cause inferior cutting performance. Therefore, a novel optimization algorithm for grinding wheel posture and geometric parameters is developed in this paper. Firstly, a parametric grinding wheel modeling method with adaptive adjustment of control variables is proposed, and a generalized grinding kinematics model for variable core radius is established. Then, by analyzing the sensitivity of cross-section parameters and the formation mechanism of the core radius, an iterative strategy based on parameter sets is established. Under the condition that the core radius is ensured in advance, the matching errors of rake angle, groove width, and overall cross-section curve are considered comprehensively to optimize the grinding wheel posture and geometric parameters. Finally, the proposed method is verified by simulation and machining. The results indicate that the proposed method can realize the envelope calculation of the helical groove with variable core radius, and optimize the grinding wheel posture and geometric parameters accurately and efficiently.