Research On The Solid Modeling Of Ball-end Miller Based On Reverse-engineering And Its Simulation Processing Technology

At present, ball-end miller is becoming more and more important in metal-cutting. As an important part of ball-end miller, helical flute is significant effect on the performance of ball-end miller. In the long-term application, the foreign technicians have accumulated abundant experience in the theory and manufacturing of the ball-end miller. Learning and absorbing the foreign advanced technology has played an important part in improving our machining technology and catching up the advanced level in the world.The reverse-engineering is a new kind of technology developed recently. Until now, there are still not the reports on studying or manufacturing ball-end miller by reverse-engineering. This thesis tries to find a new way on studying the modeling and manufacturing of ball-end miller via reverse-engineering.Firstly, we study the elementary theories of the helical flute. Its forming principle is introduced. The peripheral edge curve mathematical model helical flute mathematical model and formula for grinder design are deduced.Following above studying, the solid modeling of the ball-end miller is obtained with reverse-engineering technology. With reference to structure feature of the ball-end miller, the methods and procedure of modeling a ball-end miller are illustrated in detail. The important geometric parameters of the helical flute on miller are measured from its solid modeling. Then, another ball-end miller is modeled with above methods and this confirm versatile of the methods.On the foundation of analyzing and comparing of the existing processing methods on the helical flute, we determine the formed grinding plan of processing the helical flute on the ball-end miller. After studying usual methods of designing the formed grinding wheel, a new kind of the CAD method is proposed for designing it. This method has the characteristics of the simply and intuition. The thesis introduce in detail its method and steps. The profile curve of the formed grinding wheel is obtained and its solid modeling is produced.In the simulation processing, the cylindrical section of the helical flute on the ball-end miller is taken as the object of study. With the simulation processing software, Vericut, the special-purpose NC grinder is constructed. Its structure and the methods on defining the cutting tool are introduced in detail. The NC codes is compiled for grinding the helical flute. Then, the sectional shape of the helical flute that obtained by virtual processing is compared with the one of its solid modeling. Both are almost consistent, which prove that above method is feasible. Finally, we discuss primary causes that created error between both.In all, this thesis proposed a new way for designing and studying of ball-end miller based on reverse-engineering technology.