In designing a conical end mill with a helical front surface, the geometry of the grinding wheel has an influence on the shape of the back profile, as this study shows. For the first time, the influence of the generix of a conical circle's angle of inclination on various interference schemes has been studied. Through the combination of laser ablation and grinding, the underpoints of the helical surface were given their final shapes, indicating the standard sizes that would affect the execution's ability to be manufactured. This work will result in the engineering of a system for automated manufacturing of conical mills, as well as the development of control programs for CNC grinding and laser ablation machines. It will also enable the development of design support for cutting tool production. The work reveals analytical dependences of the value of the clearance angle, controlled at the point of the flank surface during the transition from the radius of the cutting edge to the profile section of the helical flute in the radial section, which is set from the coordinate of a parametrically defined point along the OX axis in the radial section. It has been established that the value of the radius of curvature of the cutting edge and the point of formation of the transition of the radius to the profile can significantly change the kinematic geometry of the cutter (up to nine degrees when the radius of the cutting-edge changes by 30 μmm).
A key functional role is served by the helical surfaces of carbide end mills that can be manufactured during diamond grinding wheel. Localized changes in the form of the helical surface can be caused by abrasion, high pressure, and grinding wheel wear. Therefore, it is extremely important to measure the physical samples of products with a helical surface according to the criterion of profile accuracy, rake angle and core diameter. A specialized inspection machine in reflected light can be used to obtain images across the helical groove. Manually extracting a number of defects from photos takes time. Using defect recognition algorithms, effective and quick quality control of a ground helical surface can be established. As a result, effective surface quality control can be achieved in the machine tool industry. In this study, an innovative approach to determine a defect's shape and location as well as an algorithm for removing it are presented. Both of these approaches are integrated into the technological process used to manufacture products with helical surfaces. With the goal to recognized create suggestions for image analysis using different image levels, the suggested approach provides logically smoothing histograms and limiting contrast as an image pre-processing, based on an analysis of images with useful and faulty parts. Achieved successful extraction of areas of adhesive, diffusion, abrasion and chips from the image through post-processing. The article presents a new approach to recognizing adhesive and diffusion defects on the helical surface of a mill after grinding. When developing this approach, it was revealed that areas with alternating profile changes are most susceptible to the formation of defects under conditions of increased heating of the working area, and specialized inductors for searching for defects in localized areas according to the criterion of pixel brightness intensity were proposed.
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