Optimization of simplified grinding wheel geometry for the accurate generation of end-mill cutters using the five-axis CNC grinding process

A simple geometric and optimal method is adopted for the five-axis CNC grinding of the end-mill cutters. In this research, initially a simplified parametric profile of the grinding wheel is constructed using line segments and circular arcs. The equation of the wheel swept-surface in five-axis grinding is derived. Then subjected to the flute profile design, the profile parameters of the grinding wheel, its relative location, and orientation with respect to the end-mill cutter are optimized, ensuring a specified normal rake angle. Finally, validation of the newly developed method has been performed using the CAD simulation; two virtually ground flutes are measured and compared with the given specifications. The normal rake angle is related with the radial rake angle by a relationship established in this work. This innovative approach can determine the non-standard grinding wheel that can be economically produced or dressed to accurately grind the end-mill cutters using the five-axis CNC grinding process.