This paper presents a systematic method for design and manufacturing of the circular arc type ball end rotating cutter. By using the principles of differential geometry, the correlative models and simulation results on the cutting edge are presented. On the basis of the engagement condition, approaches for solving inverse problems related to the manufacturing models are also presented. The section profile and relative feeding speeds of grinding wheels in machining processes are deduced. The effects of design and manufacture of the cutter are analysed according to the computer simulation result for the groove surface enveloped by the grinding wheel. In addition, the deviation of cutting edge, residual material and lack of land caused by the modified radial feeding speed are discussed. In order to finish the residual material and to rebuild the land of the cutter, a post-process method has been developed in this research.
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