Abstract
The helical groove shape plays a key role in ensuring the adequate flute space of many screw components. In many situations, the helical groove is machined through profiled grooving cutter, which brings a huge cost. This study establishes the mathematical model of helical groove based on cross-section and presents an approach to calculate tool path using the whirling process which machines helical groove through enwrapping movements with standard cutters. Finally, a case study and the error analysis are provided to illustrate the validity of the developed models and algorithms, which offers an alternative method for further computer aided manufacturing.
Highlights
Helical grooves are of importance in many screw components, especially those which form the flutes like screw shafts and extrusion screws
This study aims at presenting the mathematical model and the approach of calculating tool path for whirling the helical groove
While this is the typical method of thread whirling, it is feasible to cut the helical groove into shape with standard cutters as long as their tool paths are well planned as to enwrap the desired surface
Summary
Helical grooves are of importance in many screw components, especially those which form the flutes like screw shafts and extrusion screws. Jung-Fa (2006) presented a mathematical model and sensitivity analysis for helical groove machining. Ivanov and Nankov (1998) provided a generalized analytical method for the profiling of rotation tools for forming helical grooves. Sun et al (2008) presented a new simulation model for generation of the helical surface profiles on cutting tools. Onacea et al (2010) proposed to use Bezier polynomials in approximating a cylindrical helical surface with constant pitch and in-plane generatrix known in discrete form. Wang et al (2006) proposed the use of standard cutters (cutting blades), through whose enwrapping movements to produce the helical groove. This study aims at presenting the mathematical model and the approach of calculating tool path for whirling the helical groove
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