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A Novel Approach to Profile-Milling for End-Mill Flutes in 4-Axis CNC Turn-Milling Machines, Part I: Mathematical Modeling


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DOI: https://doi.org/10.15866/ireme.v13i2.16376

Abstract


In industry, two main operations are used to produce end-mills; grinding and milling. While grinding is more suited for hard end-mills, milling is more attracting in less-hard end-mills since it is more efficient and productive. However, milling the end-mills is currently conducted based on the technical experience, and to the best knowledge of the authors, no mathematical foundation has yet been established. Thus, a profile-milling approach to machine end-mill flutes in 4-axis CNC turn-milling machines is developed and introduced in this work for the first time. The approach employs the cutting edge tangents, and the rake face normals in determining a cutter’s path that ensures an accurate normal rake angle along the rake face. Knowing the cutter’s path, the approach generates a swept surface which is very essential in the profile-milling simulation and in controlling the flutes shapes. However, the profile-milling simulation is conducted in the extended part of this article over several case studies where the developed approach is validated. Overall, this approach is significantly enhancing the CNC programming techniques for multi-axis profile-milling of the end-mill flutes as well as laying a good foundation for the CAD /CAM/CAE of end-mills.
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Keywords


Profile-Milling; End-Mill Flutes; CNC Turn-Milling; Normal Rake Angle

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References


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