A new grinding trajectory adaptive adjustment algorithm for circular-arc end mill flank based on grinding contact zone control

As one of the key structural features of the circular-arc end mill, the flank directly affects its service performance such as tool life and milling efficiency. Due to the curvature discontinuity of the flank edge curves and the inflexible posture of the grinding wheel, the existing grinding trajectory algorithms are difficult to accurately control the important end mill parameters such as the relief angle and flank width, and grinding interference is easy to occur. Therefore, this paper proposes a new grinding trajectory adaptive adjustment algorithm for circular-arc end mill flanks based on grinding contact zone control. Firstly, the edge curve equations are constructed through structural feature decomposition of the end mill, and the second flank is modeled based on uniform offset densification of edge curves. Then, the grinding wheel posture model is established and the contact zone between the grinding wheel and the first flank of the end mill is calculated. A grinding trajectory adaptive adjustment algorithm is then proposed, which iteratively modifies the lifting angle and swing angle of the grinding wheel and can avoid the abrupt change of grinding postures and the grinding interference, thus realizing accurate flank grinding. Finally, the corresponding algorithm module is developed on the VC++ platform, and the effectiveness of the proposed algorithm is verified by machining simulation and grinding experiments, therefore providing technical support for the accurate grinding of circular-arc end mills.