An iteration-based algorithm for two-pass flute grinding of slide round milling tools

Solid end mill cutting tools are widely used in machining of curved surface parts in many industrial sectors, e.g., aerospace, automotive, and energy. Grinding is one of the most important processes in the manufacturing of the tools, and the movement of the grinding wheel closely influences the key parameters of helical groove cross-section, i.e., rake angle γ_o, inner core radius R_c, outer core radius R_cb, and edge width E_w, as well as chip removal capacity. However, a “closed” flute of a tool, which is one style of flute, may cause many problems if grinding it by one-pass, e.g., grinding wheel dressing to adapt to the change of flute parameters. To solve the problem in “closed” flute grinding, this paper proposes a two-pass flute grinding based on the iteration method. Within the context, some parameters and rules are identified in modeling of the two-pass grinding to control grinding wheel width and to smoothen grinding marks between the two passes of grinding. Finally, the method is implemented and validated by a set of numeric simulations and experiments. The results show that the errors of core radius, rake angle, edge width, and big core radius of the two ground tools are 1.1%, 2.0%, 3.4%, and 2.2%, respectively, which are within the designed tolerances.