Iteration-based error compensation for a worn grinding wheel in solid cutting tool flute grinding

Abstract

Abstract Solid carbide end mill are widely used in machining of curved surface parts in many areas, e.g. aerospace, automobile, and energy. In the grinding of its manufacturing, grinding wheels are worn out gradually with the grinding number increasing, resulting in the grinding error if there is no proper error compensation. In order to control the flute parameters precision for a worn wheel, this paper proposes an error compensation method by considering a boundary condition determination of a worn wheel based on an iteration-based calculation of position and orientation of grinding wheel. Within the context, the boundary contact condition between the cutting tool and wear wheel is established by identifying the relevant tool profiles associated with the worn and unworn parts of grinding wheel. On top of that, the disk of grinding wheel which generates the rake angle is detailed by considering contact angle. Finally, the method is implemented by using C#, and validated by a set of numeric simulation based on Matlab ® .