Research on models of design and NC manufacturing for ellipsoid end mill

Abstract

This paper presents a new kind of cutting tool named as ellipsoid end mill to raise machining efficiency in numerical control (NC) milling. Two types of ellipsoid end mills are developed, i.e. cylindrical ellipsoid end mill and tapered ellipsoid end mill. Three models of cutting edges (the cutting edge with constant helix angle, the orthogonal spiral cutting edge and a novel cutting edge) are established, and the corresponding numerical simulation results are also provided in graphical representation, respectively. Manufacturing mathematical models in 2-axis NC machining are established in detail for ellipsoidal end mill. The axial feed speed and the radial feed speed for 2-axis NC machining are determined accurately. Mathematical model of grinding wheel’s profile in 2-axis NC machining is provided, as well as correlative computer simulation results. Computer simulation results demonstrate the veracity of these mathematical models. An ellipsoid end mill is manufactured to verify the feasibility of ellipsoid end mill. Finally, a contrast experiment is provided to verify the applicability of ellipsoid end mill (EEM) and the advantage of EEM compared with ball end mill.