Abstract
Due to increasing demands on cutting tools, cutting edge preparation is of high priority because of its influence on the tool life. Current cutting edge preparation processes are mostly limited to generating simple roundings on the cutting edge. Multi-axis high precision form grinding processes offer great potential to generate defined cutting edge microgeometries. Knowledge about the relation between grinding strategy and material removal rate can achieve improved work results with regard to higher precision of shape and dimensional accuracy as well as enhanced cutting edge quality. Therefore, a kinematic-geometric model was developed in order to analyze the complex contact conditions during grinding cutting edge microgeometries by using a simulation approach based on the intersection of geometric bodies. The subsequent grinding tests largely validated the utilized simulation approach.
Highlights
Increasing demands on cutting tools with regard to quality and economy have led to constant progress in tool development and tool production
Maximum material removal rate Qw,max of grinding strategy I was determined at the start angle position of the mounted point, referred to as the course of the rounded cutting edge radius rβ
Edge can be Within the presented work, a kinematic-geometric model was developed in order to analyze the complex contact conditions during grinding cutting edge microgeometries
Summary
Increasing demands on cutting tools with regard to quality and economy have led to constant progress in tool development and tool production. The properties of the cutting edge influence the process characteristics and the work results in machining with defined cutting edges [1,2]. The most common production processes for cutting edge preparation are magnetic abrasive finishing, abrasive blasting, laser machining, brushing, abrasive flow machining, vibratory finishing and drag finishing. Different form grinding strategies lead to different courses of chip cross-sectional areas and different material removal rates. Knowledge about the relation between grinding strategy and material removal rate can lead to improved work results in the form of higher preciseness of shape and dimensional accuracy as well as enhanced cutting edge quality. To enable a reproducible manufacturing of cutting edge geometries, different strategies for form grinding of cutting edge microgeometries, with regard to material removal rates by using permeation simulations, are examined. The aim of this analysis is to assess these different form grinding strategies with regard to material removal rates to increase the process performance and work results
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