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Resource efficiency is gaining relevance in every aspect of production. Hence, cutting tools are exposed to high demands regarding productivity and quality. Considering the various grinding operations in tool manufacturing, flute grinding is the most significant process step as it defines the peripheral cutting edge and the rake face. Therefore, it has a substantial influence on the machining behaviour of, for example, milling tools. When it comes to helical flutes, the complex contact conditions between grinding wheel and tool blank during the multiaxial grinding process are particularly difficult to determine. Due to the lack of knowledge about those contact conditions, the grinding wheels typically used for flute grinding cannot wholly meet the actual process requirements. In order to optimise the design of the grinding wheels, a numerical model was developed. Based on that, a simulation tool was implemented to analyse the complex contact conditions during flute grinding depending on the process parameters and tool/workpiece geometry. The influence of different grinding parameters on the effective contact length, the specific material removal rate and the equivalent chip thickness was evaluated by employing the computer-based model. The generated results were then used to develop a new optimised tool concept for a more efficient flute grinding process.

Optimising the grinding wheel design for flute grinding processes utilising numerical analysis of the complex contact conditions