Geometrical process design during continuous generating grinding of cutting tools

Abstract

Modern cutting tools like end mills, drilling tools, and reamers underlie high requirements regarding geometrical accuracy, cutting edge quality, and production costs. However, the potential for process optimization is limited due to the process kinematics during grinding. Consequently, a novel tool grinding process for the manufacture of cutting tools has been developed recently at the Institute for Production Engineering and Machine Tools (IFW). This continuous generating grinding process allows the simultaneous production of all flutes and circumferential flank faces of rotational symmetrical cutting tools. The present paper focuses on the geometrical process design and develops a method to determine the necessary basic rack and process parameters in order to create a desired cutting edge geometry by continuous generating grinding. The developed method can define all parameters with an accuracy of up to 5 µm and 0.2° within a simulation in five iteration steps and allows not only the quantitative design of the cutting tool geometry but a qualitative modification of the flute geometry as well. Subsequently performed grinding tests showed that the presented method allows the design of grinding worms for continuous generating grinding of cutting tools and enables the successful implementation of these processes.