Cutting Edge Design And Manufacturing Of Non-ball End Mills And Tool Path Generation Algorithm

The complexity of surface machining becomes higher and the requirement for machining efficiency and surface quality tend to be higher as the development of aerospace, automotive and other mechanical manufacturing. A logical design and application tends to make a great contribution to improving machining efficiency and surface quality as well as declining the cost. With the development of science and technology, the computer technology makes a great contribution to reducing the difficulty of precise design and manufacturing of cutting tools and machining of complex surface. The improvement of precision in cutting tools design, manufacturing and application is very important for high-precision manufacturing. At present, the researches on cutting tools structure and geometric design are relatively few, while the cutting tool structure and geometry are the key points of performance.This thesis designed three different types of non-ball end mills including ellipsoid end mill, rotational paraboloid end mill and “8”end mill for improving machining efficiency and parts surface quality, which is suitable for the aerospace, automotive mold manufacturing industry in the field of small curvature surface processing. Three kinds of cutting edge curves of new types of cutting tools designed in this thesis are presented, which provide a theoretical basis for the precise manufacture of new cutting tools. A new parametric design platform for milling tools is developed based on MATLAB. Parametric design and visual design of the new cutting tools are achieved, which provide a simulation and verification platform for the design of cutting tools.Considering the economy of two-axis NC grinding, this thesis proposes two-axis NC grinding model of new cutting tools, puts forward the models of grinding wheel profile and calculates the axial feed rate and the radial feed rate of the grinding wheel as well. Considering the application and precision of five-axis NC grinding, this thesis proposes five-axis NC grinding models of new cutting tools, calculates the position of the grinding wheel center point and the direction of the grinding wheel axis and provides a theoretical basis and support for the precise manufacture of new types of cutting tools.Considering the wide application of three-axis NC milling, this thesis provides tool path generation algorithm and cutting tool center curves for rotary cutting tools. Considering the geometric particularity of ellipsoid end mill, rotational paraboloid end mill and “8”end mill designed in this thesis, this thesis has also built three-axis NC milling models of them respectively.In order to validate the performance of ellipsoid end mill, rotational paraboloid end mill and “8”end mill, the performance of them is studied. Compared with ball end mill, the comparison experiments on inclined plane, concave-convex surface and parametric surface are carried out. Finally the cutting performance of the tools designed in this thesis is verified.