Research on parametric modeling and shape prediction of end mill chip groove grinding process

Abstract

The chip groove as a critical structure of an integral end mill plays a key role in chip containment and evacuation. During the grinding process, it involves the maximum grinding allowance, the greatest difficulty, and the longest processing time. Therefore, it is essential to precisely predict the shape of the chip groove before the actual grinding. Based on the actual grinding process of the chip groove, a mathematical model of the grinding wheel profile in arbitrary spatial poses and the motion equation of the workpiece are established. The basic principles of chip groove formation through grinding are explained. A secondary development of SolidWorks is carried out using the Visual Basic .NET programming language. By invoking the SolidWorks API, real-time interaction with the SolidWorks assembly data is realized. A chip groove shape prediction software is developed, which provides an intuitive and simple user interface. Through this interface, users can efficiently perform parametric analysis and operations on assembly models. The effectiveness of the mathematical model, solving algorithm, and chip groove shape prediction software is validated by comparing the results with experimental. On this basis, further research is conducted on the impact of the grinding wheel shape and pose on the chip groove shape. The method proposed in this paper can quickly and accurately predict the shape of the end mill chip groove, providing a new approach for optimizing the target groove shape and tool structure design.