Modeling and numerical simulation for the machining of helical surface profiles on cutting tools.

The classical conjugation and envelope method is very accurate and effective for forward and inverse calculations of grinding helical surfaces. However, this method involves complicated mathematics and requires that the profiles be continuous. It can also result in undercutting or interference to the desired surface profiles. In this paper, a new approach is proposed to simulate the grinding process of helical surfaces on cutting tools. The paper begins with the reconstruction of cutter helicoids from sampled points. Using the recovered helical parameters from the sample points, the cross-sectional profile of the cutter surface is derived using a polynomial curve. A numerical method for calculating the profile of the grinding wheel required for the cutter surface profile is then provided. Finally, an optimization method is presented for solving the problem of inverse calculation to determine the helical surface profile for a given grinding wheel profile and setting parameters. The feasibility of the approach is tested by simulation results, which shows that the proposed approach can eliminate undesired tool-work interferences and undercutting. [ABSTRACT FROM AUTHOR]