The Research On NC Grinding Rake & Flank Faces Of Ball-end Cutters With Spiral Shape Major Cutting Edge

The ball-end cutter(BEC) is one kind of highly efficient cutting tool. It is widely used for machining complex surface on NC machine, especially in the fields of die manufacturing, motor manufacturing, aerospace manufacturing and electronic communicational products manufacturing. The grinding of BEC is the last and the very important working procedure during the manufacture; it is also the refacing working procedure of BEC, which should be done. Because it is the key of ensuring the cutting performance. In this thesis, a internal and external analyse and research about design, modeling and machining of BEC is reviewed. On the base of grinding trait of MKZ6313, in the present study, diferential geometry, ruled surface concept, coodinate transfer and numeric analyse are used to develop a mathmatical model and systematic method for the design, analyse and simulation of BEC.In this paper, the mathematical models of the orthogonal spiral-shaped curve are established and analysised, using the definition of helix angle and spiral movement. Then, based on cutting edge geometric model and machining mode of five-axis CNC grinder, the rake face with constant normal rake angle and flank face with constant orthogonal clearance angle models of ball-end cuters are discussed. By Matlab, the models are analysised and simulated.Secondly, the manufacturing processes of BEC's rake and flank faces are analysised, and the tool paths of processing them are calculated, using different algorithms. based on C++ Builder and Matlab, the automatic programme system for numerical control grinding BEC is designed. After enter the relevant parameters, NC code can be generated for five-axis grinder.Then, the main components and virtual assembly models of a five-axis NC grinder are modeled, with the software of Pro/E. In the Pro/M module, the motion for five-axis grinder grinding BEC is simulated.Finally,debugging the hardware and software of grinder, some experiments to grinding the BEC's rake and flank faces are carried out, the results are very good.Tests prove that MKZ6313 can achieve the machining movement of BEC, they also show that the mathematical models of BEC is correct and the NC automatic programming system is practicality. In this paper, the results of research prepare for processing BEC on this five-axis NC grinder.