The International Journal of Advanced Manufacturing Technology

https://doi.org/10.1007/s00170-019-04547-8

ORIGINAL ARTICLE

Optimization of simplified grinding wheel geometry for the accurate

generation of end-mill cutters using the five-axis CNC
grinding process
Muhammad Wasif 1 & Syed Amir Iqbal 1 & Aqeel Ahmed 1 & Muhammad Tufail 1 & Mahmoud Rababah 2

Received: 1 May 2019 / Accepted: 6 October 2019

# Springer-Verlag London Ltd., part of Springer Nature 2019

Abstract
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.

Keywords Five-axis grinding . End-mill cutter . Optimal CNC programming . The inverse method

Nomenclature F(l) Designed flute profile

AM Angular displacements of the Fm Ground flute profile
mill-cutter about its axis I Tangent vector of the side-cutting
BM Angular displacements about edge at point PC
the carriage assembly rotation axis J Vector along the rake face
Cr Crossover probability K Cross product of I and J
D Constant of differentiation M A plane perpendicular to the
DE Differential evolution end-mill axis
PC Point on helical side cutting edge
C(θ) on the end-mill cutter
* Muhammad Wasif S Line formed by intersection
[email protected]
between planes Γand Π
Syed Amir Iqbal
T1 Length of line segment oGP1
[email protected] T2 Length of line segment P1P2
T3 Length of line segment P4P5
Aqeel Ahmed
[email protected] PW Point with parameter ðuPW ; vPW Þ
in ℜG coordinate system
Muhammad Tufail
[email protected]
R1 Radius of circular arc P2P3
R2 Radius of circular arc P3P4
Mahmoud Rababah SV(u, v, t) Flute surface
[email protected]
WL(xWL, yWL, zWL) Grinding-wheel location
1
Department of Industrial and Manufacturing Engineering (IMD), f0f1 Line segment
NED University of Engineering and Technology, Karachi, Pakistan f1f2 Circular arc
2
Mechanical Engineering Department, Hashemite University, f2f3 Circular arc
Zarqa, Jordan f3f4 Line segment
 Int J Adv Manuf Technol

l Flute profile parameter relief surfaces [1]. The rake face is inclined with a rake angle
l f1 Length of f0f1 which has a direct influence over the cutting forces generated
l f2 Length of curve f1f2 during the machining process. Whereas, the flute geometry
l f3 Length of curve f2f3 provides the chip removal ability and rigidity to the cutter.
l f4 f5 Length of segment f3f4 Hence the geometry of the flutes eventually influences the
l f5 Length of segment f4f5 end-mill cutting life and performance. To grind a prescribed
pop Main population flute accurately, the inverse method is often adopted. In this
rnd Random number method, a grinding-wheel of a free-form profile is specially
r1 Radius of f1f2 made and used to grind the flute in a two-axis grinding pro-
r2 Radius of f2f3 cess. This is achieved by the meshing condition that is the
t Specified rake angle normal vector at each point of the contact curve between the
u Parameter of grinding-wheel grinding wheel and the cutter flute must pass through the
along its width rotation axis of the wheel (see Fig. 2). A comprehensive liter-
v Angular parameter of the wheel ature review has been reviewed and an optimal and practical
vR A unit vector passing through method is proposed to grind the flutes with the simplified and
the point PC easy to manufacture grinding wheels accurately. The new ap-
(xWL. yWL,zWL) Grinding-wheel location proach is confirmed using two virtually ground end-mill cut-
αn Normal rake angle ters, which are presented as examples in Section 6 of this
αR Radial rake angle article.
β1 Angle of line segment P1P2 In past decades, many researches were conducted to model
γS Secondary relief angle the ground solid carbide end-mills. The researches on the di-
γP Primary relief angle rect method of end-mill cutter grinding are focused on build-
ψ Helix angle ing accurate computer-based models of the end-mill cutter.
θ Rotation angle about zT-axis These researches presented the geometries of the ground flutes
μ Grinding-wheel rotation about related to the selected wheel and the relative motion during the
xG-axis grinding process.
η Grinding-wheel rotation about Kim et al. presented accurate CAD models of the end-mill
zG-axis cutter defining the auxiliary angles of the cutter necessary to
ℜT ≕ (oTxTyTzT) Tool coordinate system provide efficient cutting. Authors described the geometry of
ℜG(oGxGyGzG) Grinding-wheel coordinate system the end-mill cutter using standard CAD elements and con-
ℜM(oMxMyMzM) Machine coordinate system structed the geometry using the surface modeling [2, 3]. Ko
Γ Plane passing through point PC et al. proposed a method for constructing the machined flute
and normal to the cutting edge profile; in this method, the grinding wheel is represented by
Π Plane normal to the cutting discretization of wheel into thin circular disks. The shape cut
velocity by each disk into a cross-section of the tool is determined and
then as result of all the cuts, the profile of flute on the cross-
section is developed [4]. Ren et al. presented design of con-
1 Introduction stant pitch helical end-mill with machined using a two-axis
NC milling machine. The design of the flute profile is based
Machining of exotic metals such as Titanium, Aluminum on straight lines and circular arc. Whereas, the profile wheel of
T6061, and metal-matrix carbide (MMC) have enormously the grinding wheel was generated using the inverse method
increased the demand of carbide tools in aerospace industry. applied on the two-axis machining of the mill-cutter [5]. Wu
Due to long life and adaptive characteristics with coat- et al. established a manufacturing process model, to determine
ings, solid carbide end-mill cutters have become essen- the NC tools path and process parameters for the grinding of
tial and high-demand cutting tools in the machining in- end-mill cutter flutes. In this model, the geometry of the grind-
dustry. These end-mill cutters are well-designed cutting ing wheel is developed using the inverse method.
tools which include all the parameters of the functional Compensation in grinding is also incorporated to finish the
features such as number of flutes, primary and second- end-mill cutter [6]. Chen et al. also used inverse method to
ary relief faces, end-cutting edges with the defined rake develop the grinding wheel profile for the grinding of concave
and relief faces, and the gash [1] (see Fig. 1). cone-end mill cutters. Compensation for the machining errors
In end-mills cutters, geometry of a helical flute is bounded is also incorporated in the process parameters to increase the
between the rake face of cutting edge and the secondary relief accuracy of the model [7, 8]. Another group of researchers
surface that does not include the primary and the secondary (Chen et al.) proposed an integrated approach for the
Int J Adv Manuf Technol

Fig. 1 Main features of an end-

mill cutter

designing of grinding wheel and process parameter. Inverse [12]. Feng et al. worked on a torus-shaped grinding wheel to
method has been adopted by the author to develop the grind- machine the taper-ball end mill cutter with the constant helical
ing wheel profile. Post-processing and simulations are also angle. In this research, the normal rake angle of the end-mill
presented in the work to confirm the design approach [9, cutter is precisely grinded using a moving coordinate system
10]. Kim constructed virtual solid models of the ground end- [13]. Chen et al. proposed an analytical model to derive the
mill cutter, which were able to retrieve some geometric infor- helical groove and cutting-edge profile of the circular-arc ball-
mation from these models that were difficult to measure in end mill cutter developed during the grinding process. In this
earlier researchers [11]. Puig et al. presented a virtual grinding model, the process parameters are controlled to precisely de-
system in which a wheel motion is represented by several velop the end-mill cutter [14]. Hsieh et al. presented a simu-
Boolean operations. Solid model of the end-mill cutter is gen- lation model, to design and manufacture the geometry of he-
erated through applying several Boolean operations at the dis- lical end-mill cutter using a toroid-cone shaped revolving cut-
crete cross-sections of the cutter billet with the wheel. Finally ters. The main feature of the model is to optimize the process
rendering the multiple cross-section into the three-dimensions parameters to grind the end-mill cutter accurately.

Fig. 2 Inverse grinding of an end-mill using grinding wheel of a free-form profile

 Int J Adv Manuf Technol

Experimental validation is also conducted to check the robust- Unfortunately, all the methods discussed in the literature
ness of the model [15, 16]. Kim et al. proposed a simulation- require a grinding wheel designed using free-form profiles
based model to investigate the cutter geometry, grinding which are difficult and expensive to produce. The side-
wheel geometry, and cutter location for the multi-axis grinding cutting edges of the ground end-mills are inaccurate, and the
of end-mill cutters. In this method, an analytical approach has helical angles are smaller than the designs, leading to inaccu-
been adopted to develop the grinding wheel geometry for the rate normal rake angle. The issue of the free-form grinding
given cutter geometry using the Boolean operations [17]. F. wheels and the inaccuracy occurred in the cutting edges and in
Chen et al. proposed a novel approach to grind the accurate the prescribed rake angles is critically discussed in the litera-
normal angle and cutting edge of the CBN end-mill cutter ture [24, 25].
using the CNC tool grinder and a moving coordinate system. The objective of this research is to achieve precise flute
Simulation is also performed to validate the accuracy of the grinding of the end-mill cutter through the five-axis grinding
model [18]. Lei et al. presented two models to accurately grind machine. The novelty in this work is the optimization of the
the end-mill cutter by optimizing the five-axis grinding pa- grinding wheel path and profile based on simple geometric
rameter using the standard 1V1/1A1 wheels. In this research, features to provide end-mill flutes with exact geometries.
the major geometric parameters of the end-mill cutters are Also, the grinding wheel is not complex to manufacture as
controlled by the taking the advantage of five-axis machine. compared to the grinding wheel formed by the free-form
Simulations are also performed to study the accuracy and curves. CNC programming is presented to determine the ma-
precision of the proposed model [19, 20]. Similar work was chine settings for the generation of the end-mill cutters. The
also developed by Hein et al.; three setting parameters were same approach can be extended to other end-mills with minor
considered for the flute grinding (flute width, rake angle, and differences. In this work, the parametric models of the end-
core radius) with no control over the complete flute shape mill flute and the grinding wheel profile are developed. The
[21]. Xin et al. proposed an optimization model for the eval- generic mathematical model for the relative location and ori-
uation of grinding wheel geometry and tool path for the grind- entation of the grinding wheel and the end-mill cutter, during
ing of end-mill cutter using a multi-axis grinding machine. the five-axis grinding process are derived, the wheel path to
VERICUT is used to simulate the results for the validations grind the accurate flute on the end-mill cutters are also derived
[22]. Han et al. presented a parametric model of the end-mill considering the normal rake angle of the cutter. Finally, the
cutter using straight lines and arc and defined the rake and accurate end-mill ground model is compared with the flute
relief angles on the cutter. Grinding wheel geometry is deter- design model.
mined for the cutter and process parameters are determined for The cutting force models for grinding operations can also
the grinding [23]. be incorporated, to optimize the cutting parameters and to
Tool manufacturers have designed few accurately ground, predict the tool’s deflections, and to predict the shapes of the
new end-mill cutters with tight tolerances of the important actual end-mills produced from the grinding operations.
functional features. To grind a prescribed flute, the inverse However, this is beyond the focus of this research work, and
method is vastly adopted. In this method, a profile of the hence generating the end-mill shapes is limited to the geomet-
grinding wheel is determined using the machine configura- ric interaction with the grinding wheel.
tion, where a two-axis machine is normally used, in which This research article consists of seven sections, among
the tool grinding configuration is defined by moving the which the first section has already introduced the research
wheel and rotating the cutter simultaneously. Most of the re- work. In the next two sections, parametric models of a generic
search articles cited above proposed accurate grinding using end-mill cutter and a grinding wheel profile are defined, while
the inverse method. The researches in cited articles mainly in the fourth section, the mathematical relationship of the end-
applied the inverse method to the end-mill cutters with the mill cutter geometry with the wheel geometry is developed. In
helices of constant pitches, concave-cone end-mills, end- the fifth section, the five-axis CNC programming is presented,
mills with circular arc, ball end-mills with constant pitch he- whereas the sixth section addresses the application of this
lical flutes, toroidal end-mills with concave-arc generators, mathematical model with two numerical examples. Finally,
concave arcs ball end-mill cutters, circular arc ball end-mill the last section concludes the research work.
cutters, toroidal cone end-mills, and truncated-cone ball end-
mills. The core activities of these research works include (1)
determination of grinding-wheel profile for the two-axis
grinding, and (2) calculating the end-mill rotation speed and 2 Flute design of cylindrical end-mill cutter
the feed rate of grinding-wheel. To grind the rake face with the
defined normal rake angle accurately, two group of re- To model a flute of a cylindrical end-mill cutter, parametric
searchers used special grinding wheels to generate the rake model of a cylindrical blank is developed. Analytical model of
faces of tapered ball end-mill cutters [4–23]. a side-cutting edge on the cutter billed is also developed.
Int J Adv Manuf Technol

Following sections defined these two steps to define the flute The parametric equation of f1f2 is described as
design of the cutter. 2   3
l−l f 1
6 r1 sin αR − r1
:
7
Fðl Þ ¼ o1 þ 6  7 ð2Þ
l−l f1
2.1 Flute profile of end-mill cutter
4 5
−r1 :cos αR −
r1
Flute geometry is especially important to the cutting func-  
where l∈ l f 1 ; l f 2 and l f 2 be the length of curve f1f2 bounded
tion of the end-mills, since each cross-sectional of a flute
between the angles subtended by radius r1 from point f1 to f2
includes the rake face related with the rake angle which
on the curve.
directly affects the cutting forces and temperature. Also, it
Equation of the third circular arc segment f2f3 of radius r2 is
is tangent to the core of the tool thus it determines the
given by
core size, which is a key factor of the tool rigidity [2–4].
 3
Moreover, proper geometry of the flute profile can easily
2
−r 2 :sin αR − l f 2 −l f 1 þ l−l f 2
break and efficiently evacuate chips during the milling r1 r2  7
ð3Þ
6
Fðl Þ ¼ o2 þ 6  7
l f −l f l−l f2
process. To generalize the end-mill cutter, a four-flute tool
4 2 1
5
r2 :cos αR − þ
r1 r2
is considered in this research, for which a tool blank is
first considered to define the reference system of the tool.  
A tool blank is first considered to define the reference where l∈ l f 2 ; l f 3 and l f 3 be the length of curve bounded
system in the tool. A tool coordinate system RT ¼ between the angles subtended by radius r2 from the point f2
to f3 on the curve.
ðoT xT yT zT Þ is considered such that the origin oT is rigidly
For a given length of line segment f4f5, l f 4 f 5 the
attached at one of the tool end, secondly the zT-axis co-
incide with the tool axis directing toward the tool length parametric equation of the arc segment, f3f4 can be rep-
and finally the plane xTyT is perpendicular to the zT-axis, resented as
where the xT-axis passes through the side-cutting edge.

l f 4 f 5 :cosγ P


cosγ S

Figure 3 illustrates the blank of an end-mill cutter with Fðl Þ ¼ þ ðl f 4 −l Þ : ð4Þ
rT −l f 4 f 5 :sinγ P −sinγ S
its tool coordinate system.
Figure 4 illustrates a profile of a four-flutes end-mill cutter
in a plane parallel to the xTyT plane. A flute profile in the
defined plane is bounded between the two circles of radius
rT and rC, which are tool circle radius and core radius, respec-
tively. The profile is defined using three segments: (1) line
segment f0f1, making radial rake angle αR with the xT-axis,
it forms the rake face of the side-cutting edge of the end-mill;
(2) circular arc f1f2 of radius r1, tangent to both f0f1 and the
core circle; and (3) circular arc f2f3 of radius r2, tangent to the
arc f1f2, and the line segment f3f4. As shown in Fig. 4, line
segment f3f4 is tangent to the arc f2f3, makes a secondary relief
angle γs with the xT-axis and generates the secondary relief
surface of the side-cutting edge in 3D model. Another line
segment f4f5 in inclined with an angle of primary relief angle
γp which generates the primary relief surface of the side-
cutting edge. In the conventional manufacturing processes,
the flute between f0 and f3 is often ground in one path with a
special grinding wheel where the primary and the secondary
relief surfaces are then produced with a standard grinding
wheel in two separate paths.
Flute profile length is defined by a parameter l. The para-
metric equation of segment f0f1 is given by



rT cosαR
Fðl Þ ¼ −l : ð1Þ
0 sinαR
 
where l∈ 0; l f 1 and l f 1 be the length of line f0f1. Fig. 3 A blank of end-mill cutter with tool coordinate system
 Int J Adv Manuf Technol

3 Geometry of grinding wheels

 
where l∈ l f 3 ; l f 4 and l f 4 be the length of segment f3f4.
Similarly, the parametric equation of the last line
segment, f4f5, can be expressed as Grinding wheels are the abrasive tools used to grind the solid


 carbide end-mill cutters where standard wheels are largely used
0 cosγ P in manufacturing due to the cost effectiveness. However, to ma-
Fðl Þ ¼ þ ðl f 5 −l Þ: ð5Þ
rT −sinγ P chine some special shapes, non-standard grinding wheels with
  complex profiles are proposed in earlier research [4–23]. These
where l∈ l f 4 ; l f 5 and l f 5 be the length of segment f4f5. grinding wheels are more expensive to manufacture, especially
Hence generally, l f 1 can be the length of the flute profile at the wheels constructed with free-form profiles. Therefore, in this
point f1 starting from point f0 where i ∈ {0, 1, …, 5}, and can work, a grinder wheel profile consists of line-line-circle-circle-
be obtained together with o1 and o2 using the geometric line is adopted (shown in Fig. 5). Since the profile includes some
relations. simple geometric features, the cost of making such grinding
wheels is expected to be lower than grinding wheels having
2.2 Helical side-cutting edge free-form curves which need non-traditional ways of contouring,
especially in case of splines. The parameters of these geometric
Each side-cutting edge can be defined by a helix having a features are optimized to accurately grind the end-mill flutes with
helical angle ψ on the blank of the tool [2–4]. The parameter tight tolerances of its designs.
of the side-cutting edge can be defined by rotation angle θ Consider a coordinate system RG ¼ ðoG xG yG zG Þ, which
about the zT-axis. Its parametric equation C(θ) is expressed is defined in following way: first the origin oG is rigidly at-
in RT as tached at the center-face of the wheel, secondly the xG-axis is
2 : 3 directed along the radial direction of the wheel, and finally the
rT cosθ zG-axis is directed along the width of the grinding wheel,
CðθÞ ¼ 4 rTrTsinθ 5 ð6Þ where the yG-axis is defined by the right-hand rule.
6 : 7
:θ
tanψ The grinding-wheel profile is described using five seg-
ments: (1) line segment oGP1 aligned horizontally, emerging
where angle θ is measured in radians. from point oG and having a length of T1; (2) another line

Fig. 4 Cross-section of a four-

flutes end-mill cutter
Int J Adv Manuf Technol

Fig. 5 Proposed grinding wheel

profile

segment P1P2 making an angle β1 with the xG-axis and having 2 3

a length of T2; (3) circular arc P2P3 of radius R1 with center −R1 :sinβ1
O1, tangent to the line segment P1P2; (4) another circular arc O1 ¼ P2 þ 4 0 5 ð9Þ
R1 cosβ 1
:
segment P3P4 having radius R2 with center O2, tangent to the
2 3
arc P2P3 as shown in Fig. 5; and (5) a line segment P4P5 along ðR1 þ R2 Þ:sinβ 2
the xG-axis and having a length of T3. The profile is closed O2 ¼ O1 þ 4 0 5 ð10Þ
using line oGP5 along the wheel axis. ðR1 þ R2 Þ:cosβ2
The parametric equation of the profile can be given by
Pxi
2 3
8 u y
> T1 þ 0 ≤ u ≤T 2 :sinβ 1 Similarly, the profile points Pi ¼ 4 Pi 5, where i = {1, 2, …,
tanβ
>
Pzi
>
>
< 1
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi ffi
RðuÞ ¼ Ox þ R1 2 − u−Oz 2 T 2 :sinβ 1 ≤ u ≤Pz3 ð7Þ
>
> 1 1
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi 5}, were calculated in terms of the geometric parameters as
: Ox − R 2 − u−Oz 2
> 2 3
Pz3 ≤ u ≤T T1
>
2 2 2
P1 ¼ 4 0 5,
where u be the parameter of grinding-wheel along its width. 0
Therefore, the solid model of the grinding wheel can be
2 3
2
T 1 þ T 2 :cosβ 1
3 R1 :sinβ 2
generated by revolving the profile of the grinding wheel about P1 ¼ 4 0 5, P3 ¼ O1 þ 4 0 5,
the zG-axis or rotation axis of the wheel. Considering v as the T 2 :sinβ1 R1 :cosβ2
angular parameter of the wheel, where the angular displace-
2 3 2 3
R2 sinðβ 2 þ βÞ
: T3
ment is measured in radian, the parametric 3D model of the P4 ¼ O2 þ 4 0 5, and P5 ¼ 4 0 5
wheel can be given by R2 :cosðβ2 þ β Þ T
2 3
RðuÞ:cosv
Wðu; vÞ ¼ 4 RðuÞ:sinv 5 ð8Þ
u 4 Relationship between end mill cutter flute
and grinding wheel
In the preceding equations, the circular arcs origins
2 x3
Oi In the earlier two sections, parametric models of end-mill cut-
y
Oi ¼ 4 Oi 5, where i = {1, 2}, were calculated as ter and profile of the grinding wheel have been developed. In
Ozi this section, the two profiles are mathematically related with
each other. So that these are inside the five-axis flute grinding
 Int J Adv Manuf Technol

CNC machine such that the two profiles are engaged together BM axes. In the proposed method of five-axis grinding of tool,
and follow the meshing condition, which is later described in location and orientation of a grinding wheel should be deter-
Section 4.2. Therefore, the structure of five-axis flute grinding mined first, and then its profile can be optimized. This will
machine has been defined, and the relation between the cutter ensure that the cutting edge of the cutter and the normal rake
and the grinding wheel with reference to the CNC machine are angle of its rake face are accurate and are not altered by the
developed. wheel geometric parameters.

4.1 Structure of tool grinding machine

4.2 Relative location and orientation of grinding
The simple geometry of cylindrical end-mills makes it possi- wheel
ble to be ground using two-axis grinding machines. However,
the later processes for the further detailing of rake angles along The core objective of the five-axis tool grinding is to generate
the side cutting edge are also employed. To avoid the subse- the helical side-cutting edge and the rake face with an exact
quent processes on the end-mill cutters, five-axis grinding of normal rake angle. To achieve this objective, tangency between
the tool using a CNC grinding machine is employed. A five- the grinding wheel and the rake face of the cutter at a point
axis tool grinding CNC machine is shown in Fig. 6. The ma- during the grinding is maintained. Hence, the flute machining
chine contains five axes, in which three primary axes are XM, can be represented by a mathematical model that is the normal
YM, and ZM, among which XM axis is used to denote the vector of the rake face, derived at the side-cutting edge, and the
displacement of the end-mill carriage assembly along the lon- unit normal of the grinding-wheel, both be aligned together at
gitudinal direction of the bed and YM and ZM axes represent the contact point but with opposite directions. This mathematical
the linear displacement of the grinding wheel along the height- model is the principle core of determining the grinding-wheel
wise direction and the lateral direction of the machine bed, position and orientation in five-axis tool grinding [24, 25].
respectively. The two secondary axes, AM, and BM, represent Grinding wheel position and orientation can be evaluated
the angular displacements of the mill-cutter about its axis and using a unit normal vector at the rake face. The process of
about the carriage assembly rotation axis, respectively. This finding the normal is illustrated here. A point PC is considered
CNC machine can simultaneously perform the linear motion on the helical cutting edge C(θ) on the cutter in the RT coor-
along XM, YM, and ZM axes and the rotation about AM and dinate system shown in Fig. 7. The first step is to construct a

Fig. 6 Five-axis CNC grinding

machine
Int J Adv Manuf Technol

Fig. 7 Rake face and its unit normal vector

plane Γ passing through the point PC and perpendicular to the

cutting edge. The tangent vector I of the side-cutting edge at Fig. 8 CNC programming principles for the end-mill flute grinding
point PC can be easily obtained, and the plane Γ is perpendic-
ular to I. The second step is to establish a plane Π, normal to orient the grinding wheel, the two vectors must be aligned to-
the cutting velocity, where direction of the cutting velocity can gether, hence the grinding wheel is rotated about xG-axis with an
be imagined by a tangent on the cross section (circular) of the angle μ and about zG-axis with an angle η. Thus, the orientation
tool blank at the point PC. Hence, the plane Π passes through of the grinding wheel includes the two angles, μ and η. By
the zT-axis and point PC. The third step is to construct the rake solving the vector relationship presented in Fig. 7, the orienta-
face. The intersection between planes Γ and Π forms line S. tion of grinding-wheel in term of angles μ and η are given by
The given normal rake angle αn of the end-mill cutter can be 8 !
measured on plane Π, which is the angle between line S and > −1 c
>
> sin −ϕ
vector J along the rake face. Thus, the vector J is determined
p ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
a2 þ b2 !
<
for a given normal rake angle αn. The Rake face is defined by μ¼ ð11Þ
> −1 c
> π−sin pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi −ϕ
>
vectors I and J, hence its unit normal K can be determined by :
a2 þ b2
the cross product of I and J. The equation of the unit normal of
the rake face and its derivation are rendered in another re-
search article [24]. where sinϕ ¼ pffiffiffiffiffiffiffiffiffi
a
2 2
, sinϕ ¼ pffiffiffiffiffiffiffiffiffi
b
2 2
, a = cos β1, b = − sin v ·
a þb a þb
It is necessary to relate the two-surface tangent to each sin β1, and c = cos αn · sin ψ.
other in a single reference system and for the condition of
tangency between the end-mill cutter flute and the grinding- η1 if η1 ¼ η3;4
η¼ ð12Þ
wheel surface. The two conditions must be met: (1) the align- η2 if η2 ¼ η3;4
ment of the unit vectors on the two surfaces at that contact
point, and (2) the contact between a point on the end-mill where
8 !
cutter flute and the grinding wheel. Based on the unit normal > −1 c 1
< sin pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi −ϕ1
>
>
K, the relative orientation of the wheel in RT coordinate sys- a1 2 þ b1 2 !
>
η1;2 ¼ ð13Þ
tem is determined. > −1 c1
: π−sin
>
>
> pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi −ϕ1
It can be seen in Fig. 8 that the normal N on the grinding a1 þ b1 2
2

wheel surface is of opposite direction to that of unit normal K on

the rake face. Therefore, for the first condition, that is to properly and,
 Int J Adv Manuf Technol

From Figs. 6 and 8, it can be noted that the angles μ and η

in the machine can be adjusted by rotating BM and AM axes,
respectively.
For the second condition, consider a point Pw on a surface
of grinding wheel which coincides with point PC on the side-
cutting edge C(θ). Since the surface parameters of the grinding
wheel are defined by u and v, the point Pw with its parameters
can be expressed by Pw ðuPW ; vPW Þ in RG coordinate system.
To find the grinding wheel location, adopting the proper trans-
formations from RG to RT coordinate system using the values
of μ and η found, the point Pw can be presented in RT coor-
dinate system as

PTW ðuPW ; vPW Þ¼Rotx ðηÞ:TranðxWL ; yWL ; zWL Þ:Rotz ðμÞ: ð15Þ

G 
P W ð uP W ; v P W Þ
Fig. 9 Span of radial rake angle 1

a1 b1
sinϕ1 ¼ pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
2 2
, cosϕ1 ¼ pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
2 2
, a 1 = sin β 1 ∙
ða1 Þ þðb1 Þ ða1 Þ þðb1 Þ
where
cos v, b1 = − cos β1 · sin μ − cos μ ∙ sin β1 ∙ sin v, and c1 = − 2
cosη −sinη 0 0
3 2
1 0 0 xWL
3
cos ψ ∙ cos αn ∙ sin θ + cos θ ∙ sin αn, and 6 sinη cosη
Rotz ðηÞ¼4
0 0 7
ðx ; y ; z Þ¼
6 0 1 0 yWL 7
0 0 1 0 5;Tran WL WL WL 4 0 0 1 zWL 5
0 0 0 1 0 0 0 1
8 !
> −1 c 2
1 0 0 0
< sin
2 3
>
> pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi −ϕ2
a2 2 þ b2 2 !
>
η3;4 ¼ ð14Þ and Rotx ðμÞ¼64 00 cosμ
sinμ
−sinμ 0 7
cosμ 0 5
> −1 c2 0 0 0 1
: π−sin
>
>
> pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi −ϕ2
a2 þ b2 2
2 By coinciding both points (Pw ðuPW ; vPW Þ andPC(θ)),
the grinding wheel location, WL(xWL, yWL, zWL), can
where be derived as
a2 b2
sinϕ2 ¼ pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi , cosϕ2 ¼ pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi, a 2 = cos β1 ∙



2 2
ða2 Þ þðb2 Þ 2 2
ða2 Þ þðb2 Þ xWL cosη sinη c1
¼
sin μ + sin μ ∙ sin β1 ∙ sin v , b2 = sin β1 ∙ cos v and c2 = cos ψ yWL −sinη cosη c2   ð16Þ
∙ cos αn ∙ cos θ + sin θ ∙ sin αn . rT : uP W
zWL ¼ θ−uPW :cosμ−sinμ:sinvPW : T 1 þ
tanψ tanβ 1

where
 
u PW :
c1 ¼ rT cosθ−uPW :sinμ:sinη− T 1 þ ðcosη:cosvPW −cosμ:sinη:sinvPW Þ
 tanβ 1 
u PW
c2 ¼ rT sinθ þ uPW :sinμ:cosη− T 1 þ :ðsinη:cosvPW þ cosμ:cosη:sinvPW Þ
tanβ 1

The relative location of the grinding wheel WL(xWL, yWL,

zWL) with the end-mill cutter in the RM (machine coordinate
system) can be determined with the given machine specifica-
tions. Adopting the transformation between the wheel and the
end-mill cutter in such way (i.e., Eq. 15) to describe the

Table 1 Parameters of end-mill cutter—example 1

Tool radius Core radius Tool length Helical Radial rake

(mm) (mm) (mm) angle (°) angle (°)

25 12.5 60 45 6
r1 mm r2 mm γP° γS°
Fig. 10 Ground flute profile generated by a grinding wheel moving along 8 21 4 45
path t
Int J Adv Manuf Technol

10

5
Grinding-wheel axis

mm
-5
Grinding-wheel profile
of a free-form curve

-10

-15
30 35 40 45 50
Radius (mm)
Fig. 11 Flute profile of the end-mill cutter—example 1

(a) Profile Generated through the Inverse-Method

grinding wheel location WL(xWL, yWL, zWL) in terms of a
stationary coordinate system coinciding with the end-mill co-
ordinate system at η = 0. In other words, the end-mill is rotated Grinding-wheel axis
25
about its axis by angle η when describing the grinding wheel
location. For cylindrical end-mills, the variables xWL, yWL, and
μ defines the initial position of the end-mill cutter in the ma- 20
chine and remains constants during the grinding process.
These can be used as setting parameters in the two-axis grind- Circular arc

ing machines. Whereas, rotation of tool about the AM axis and 15

the displacement of the wheel along the tool axis form the
mm

Grinding-wheel profile
helical path of the contact to grind the end-mill cutter. with simple geometry
10

Circular arc
5 Optimization of grinding wheel and CNC 5
programming
Line

The parametric optimization of the grinding wheel profile is 0

performed, to minimize the largest deviation between the 25 30 35 40 45 50
Radius (mm)
cross-section of the ground flute profile and the given flute
profile. With the optimal grinding wheel, its WLs along the
side-cutting edge are calculated such that the normal rake (b) Profile Generated through the Current Method
angle is the same as specified. The specified value is obtained Fig. 12 Profile of the grinding wheel generated through the inverse and
from a relation derived between the normal and the radial rake current methods—example 1. a Profile generated through the inverse
angles. Finally, the flute of the end-mill can be precisely method. b Profile generated through the current method
ground with the optimal grinding-wheel in a five-axis grind-
ing process.

Table 2 Location and orientation of grinding wheel—example 1 Table 3 Parameters of grinding wheel profile—example 1

μ (°) η (°) xWL (mm) yWL (mm) zWL (mm) T1 (mm) T2 (mm) β1 (°) β2 (°) R1 (mm) R2 (mm)

33.075 − 30.834 59.004 − 0.506 − 13.475 31.34 15 19.916 64 1.805 428

 Int J Adv Manuf Technol

Fig. 13 Ground verses designed

flute profiles of the end-mill
cutter—example 1

5.1 Relationship between normal and radial rake cutting edge which is shown in Fig. 9. Another unit vector vR
angles passing through the point Pc makes the radial rake angle αR
(shown in Fig. 9). These two vectors can be given by
At any cross-section perpendicular to the end-mill axis, the 2 3
side-cutting edge intersects the cross-section at point Pc. A cosθ
unit vector vc defines the location of the point Pc in the OT vC ¼ 4 sinθ 5 ð17Þ
0
coordinate system, where angle θ is the parameter of the side

Fig. 14 Error curve of the ground

flute profile—example 1
Int J Adv Manuf Technol

Fig. 15 End-mill cutter generated

with the optimized grinding-
wheel—example 1. a End-mill
cutter generated with an exact
side-cutting edge. b End-mill
cutter generated with an accurate
normal rake angle

(a) End-mill Cutter Generated with an Exact Side-Cutting Edge

(b) End-mill Cutter Generated with an Accurate Normal Rake Angle

2 3
cosðθ−αR Þ vR :K ¼ 0 ð19Þ
vR ¼ 4 sinðθ−αR Þ 5 ð18Þ
0 Simplifying Eq. (19), the mathematical relationship within
the normal and the radial rake angles of the end-mill cutter can
be represented as

Since the unit vector vR is formed on the rake face, αn ¼ tan−1 ðtanαR cosψÞ ð20Þ
therefore, following relation for the cross product of
vector vR and the unit normal K on the rake face can Similar relations can be used to relate the normal relief
be considered. angles with the radial relief angles.
 Int J Adv Manuf Technol

Table 4 Parameters of end-mill cutter—example 2 formed by the transforming the effective grinding edge
Tool radius Core radius Tool length Helical Radial rake W(u,v). The parameters η, xWL, yWL,zWL, and μ can be deter-
(mm) (mm) (mm) angle (° angle (°) mined using the condition of meshing as described in the
Section 4.2 and applying the envelope theory, that is
15 8 40 20 15
r1 mm r2 mm γP° γS° ∂SV ∂SV ∂SV
¼0 ð22Þ
3 9 5 30 ∂u ∂v ∂t

Using the Eq. 22, parameters η, xWL, yWL,zWL, and μ and

now known, using that, set of trajectories of effective grinding
5.2 Determination of the ground flute profile
edge W(u,v) are known, which forms the swept envelope or
machined flute surface. The ground flute profile, Fm, is the
To optimize the grinding wheel profile for the minimum de-
intersection of the ground flute with a plane M perpendicular
viation of the ground flute profile with the pre-defined flute, it
to the end-mill axis (Fig. 10). However, it is too complicated
is critical to establish an analytical model of the ground flute
to find a closed-form equation of ground flute profile.
profile. In general, moving the grinding wheel with the wheel
Therefore, a numerical method is employed to generate a
path t forms a swept-volume and can be represented as
group of points representing the profile.
SVðu; v; t Þ ¼ ROTz ðηðt ÞÞ:TranðxWL ðt Þ; yWL ðt Þ; zWL ðt ÞÞ:


Wðu; vÞ 5.3 Optimization of the grinding wheel profile
ROTx ðμðt ÞÞ :
1
ð21Þ Flute profile F(l) is designed as a reference of the flute
shape, and the ground flute profile Fm is eventually deter-
where the wheel path ‘t’ is the trajectory followed by the mined by the grinding wheel and its five-axis grinding
effective grinding edge W(u,v) and generated by the transfor- path. Thus, the geometric parameters of grinding wheel
mation above with the parameters η, xWL, yWL,zWL, and μ. profile is to be optimized in order to ensure that the actual
Here, SV(u,v,t) describes the swept envelope (ground flute) flute profile is in good agreement with the designed flute

Fig. 16 Flute profile of the end-

mill cutter—example 2
Int J Adv Manuf Technol

profile. After specifying the geometry of the wheel profile

and the point Pw, the ground flute profile Fm can be de-
5
termined, which is then compared with the design flute
profile F(l). Thus, an optimization process is employed
for the wheel geometric parameters and the location of Grinding-wheel axis

point Pw in order to minimize the deviation between the 0

two profiles. Hence, the special grinding wheel with sim-

mm
ple geometries can be made economically and can be used
in the grinding of the cutter flute.
According to the profile of the grinding wheel rendered in -5
Grinding-wheel profile
Section 3, the geometric parameters are T1, T2, β1, β2, of a free-form curve
R1, and R2 (see Fig. 5). For the contact point Pw, the parame-
ters are uPw and vPw . The objective function of the deviation
-10
between the flute profiles and the designed flute can be con-
structed as
25 30 35 40
Radius (mm)
Minimize d ðT 1 ; T 2 ; β1 ; β 2 ; R1 ; R2 ; uPW ; vPW Þ
¼ maxk Fm − Fðl Þk ð23Þ (a) Profile Generated through the Inverse-Method

To elaborate more on this equation, for certain path and ge-

Grinding-wheel axis
ometry of the grinding wheel, the machined flute profile Fm is 20
obtained and compared with the designed flute profile F(l). The
maximum deviation between both profiles along the three seg-
ments (f0f1, f1f2, and f2f3) is obtained as distance d. Minimizing
the maximum deviation between both profiles (distance d) will 15
lead to optimal values of the grinding wheel path and geometry
that will produce end-mills with exact flute profiles. Circular arc

Since this model is a complicated global optimization

mm

model, the differential evolution method is adopted in 10 Grinding-wheel profile

this work. The result of the optimization includes a set with simple geometry
of values of the grinding wheel geometric parameters
and the parameters of point Pw ðuPw ; vPw Þ.
5

5.4 Applying differential evolution Circular arc

Line

To solve the optimization problem efficiently, a global optimi- 0

zation solver, differential evolution (DE), is employed. The
main procedure of the DE method is explained here. First, 25 30 35 40
the method randomly selects three elements from the main Radius (mm)
population (pop) of size m at a time say 7, 8, and 23. Then,
element 7 will form the base vector and both 8 and 23 will (b) Profile Generated through the Current Method
form the differentiation vector. The ith element is now created
Fig. 17 Profile of the grinding wheel generated through the inverse and
according to the rule current methods—example 2. a Profile generated through the inverse
method. b Profile generated through the current method
for i =1 m
if rnd < Cr
element = pop(7) + D(pop(8) pop(23)) where rnd is a random number, Cr is the crossover probability,
else and D is the constant of differentiation. This procedure will
element = pop(i) form P new elements that are evaluated and will become part
end of the new population if they have better function values than
end the original elements in the population; otherwise, these ele-
ments will be discarded.
 Int J Adv Manuf Technol

Table 5 Location and orientation of grinding-wheel—example 2 grinding flutes of end-mills are conducted. For the given end-
μ (°) η (°) xWL (mm) yWL (mm) zWL (mm) mill flute profile, the grinding wheel profile is optimized.
Five-axis CNC grinding programming for the cutter flute is
65.430 − 32.335 44.508 6.120 − 8.198 computed, and the results are illustrated. Two end-mill cutters
with different flute profiles are ground and presented as ex-
amples in comparison with the flutes ground through the in-
verse method.
Table 6 Parameters of grinding-wheel profile—example 2
6.1 Example 1
T1 (mm) T2 (mm) β1 (°) β2 (°) R1 (mm) R2 (mm)

27.35 9 16.88 53.76 1.18 16.81 In example 1, the first end-mill cutter is ground using the
optimized grinding wheel. The given values of flute profile
geometry of the end-mill cutter are presented in Table 1,
Taking the difference between two elements is much sim- whereas the flute profile geometry is plotted in Fig. 11.
ilar to taking the derivative. However, as the two elements are For the given geometry of flute profile, the new approach
quite apart, this difference is more a global measure of the has been applied to the CNC grinding programming for the
objective function changes. As only the new elements with five-axis grinding. The grinding wheel location (xWL, yWL,
better objective functions are adopted for the new generation, zWL) and orientation (μ and η) are presented in Table 2.
the solution will approach to the global minimum. The output To optimize the grinding wheel profile, populations of 50
results are quite satisfactory as briefly discussed in the next elements were used, and 52063 function evaluations were
section with practical examples. required to minimize the smallest deviation of the ground flute
with the designed flute profiles below 0.324 mm. To show the
advantage of current method over the conventional inverse
6 Applications method. The wheel profile generated through the inverse
method is a free-form curve plotted in Fig. 12a. So, it is diffi-
To validate the current research and to demonstrate the advan- cult to dress and make the grinding wheel. However, using the
tages of this method over the inverse method, two examples of approach introduced here, the grinding wheel cross-section is

Fig. 18 Ground verses designed

flute profiles of the end-mill 15
cutter—example 2

Designed
flute profile in
10
the solid curve

5
Machined
flute profile in
the doted curve
mm

0
Core circle

-5

End-mill circle
-10

-15

-15 -10 -5 0 5 10 15
mm
Int J Adv Manuf Technol

Fig. 19 Error curve of the ground flute profile—example 2

optimized using simple geometric features as demonstrated in For the given flute profile, the new approach has
Fig. 12b. The values of the profile parameters of the grinding been applied to develop the cutter location and orienta-
wheel are represented in Table 3, where T2 is pre-set to 15 mm tion for the five-axis grinding of the cutter flute.
prior the optimization, and the location of point Pw was deter- Table 5 presents the location and orientation of the
mined from optimization as uPw =3.89 mm and vPw =153.59°. grinding wheel (example 2).
Performing the five-axis grinding simulation using the The same population size is used as in the first example; the
grinding wheel obtained from the optimization process, the optimal solution is reached after 7682 function evaluations.
ground flute profile can be easily computed. To compare the The maximum deviation between the designed and the ground
two approaches, the ground and designed profile of the cutter flute profile is 0.139 mm.
are plotted together in Fig. 13, whereas the error curve is The values of the grinding wheel profile parameters
plotted in Fig. 14. are listed in Table 6, where T2 is pre-set to 9 mm prior
Moreover, the end-mill cutter ground with the optimized the optimization, and the location of point Pw was de-
grinding wheel (example 1) is generated using the Boolean termined from optimization as uPw =1.68 mm and vPw
operations as shown in Fig. 15. The side-cutting edge of the =165.48°.
end-mill cutter generated from simulation is perfectly coinci- Same as presented in the example 1, a free-form curve; for
dent with the designed cutting edge (Fig. 15a), and the normal the given flute profile is plotted in Fig. 17a. To compare with
rake angle measured on the end-mill at a plane normal to the the current approach, the optimal grinding wheel profile is
cutting edge is found accurate (Fig. 15b). plotted in Fig. 17b.
Using the optimized grinding wheel, the ground flute pro-
file is computed and compared with the designed profile in
6.2 Example 2 Fig. 18, whereas the profile error curve is plotted in Fig. 19.
The end-mill ground with the optimized grinding wheel for
In example 1, another end-mill cutter of radius 15 mm is the cylindrical end-mill of example 2 is also simulated using
ground. The values of the parameter of the flute profile are the Boolean operations and shown in Fig. 20. The side-cutting
shown in Table 4, whereas the profile geometry is shown in edge obtained is accurate within the tolerance, and the normal
Fig. 16. rake angle is accurate.
 Int J Adv Manuf Technol

Fig. 20 End-mill cutter generated

with the optimized grinding-
wheel—example 2. a End-mill
cutter generated with an exact
side-cutting edge. b End-mill
cutter generated with an accurate
normal rake angle

(a) End-mill Cutter Generated with an Exact Side-Cutting Edge

(b) End-mill Cutter Generated with an Accurate Normal Rake Angle

7 Conclusions grinding wheel profile geometry is optimized for the given

geometry of the end-mill. This grinding wheel replaces the
For the given parametric models of end-mill cutter, the grind- expensive free-form grinding wheels commonly used in the
ing wheel profile using the analytical geometries has been inverse method. To grind the flute of an end-mill with the
developed. Rather than using the free-form geometries and accurate flute geometry and the defined rake and relief angles,
impractical grinding-wheels (such as B-spline curves or the grinding wheel location and orientation are determined so
NURBS) which are impractical to machine, simple geometric that the rake face is ground with the defined normal rake
features (such as lines and circular arc) of the grinding wheel angle, and the maximum deviation error between the ground
profile are used, which are easier to manufacture. Using the flute and its designs is minimized. Finally, the end-mill cutter
direct method and the differential evolution technique, the is virtually produced in the CAD/CAM software and the
Int J Adv Manuf Technol

parameters of the end-mill cutter are evaluated. The produced 6. Wu C, Chen C (2001) Manufacturing models for the design and NC
grinding of a revolving tool with a circular arc generatrix. J Mater
side-cutting edge of the end-mill are found to be accurate as
Process Technol 116(2):114–123. https://doi.org/10.1016/S0924-
defined in the given designed. Overall, this work significantly 0136(01)00996-7
contributes to the research of the flute grinding of the end-mill 7. Chen W, Lai H, Chen C (2001) A precision tool model for concave
cutters and provides an accurate geometrical model for the cone-end milling cutters. Int J Adv Manuf Technol 18(8):567–578.
https://doi.org/10.1007/s001700170
ground flutes. This work does not only provide the accuracy
8. Chen W, Chen W (2002) Design and NC machining of a toroid-
in the manufacturing of end-mill cutters but also reduces the shaped revolving cutter with a concave-arc generator. J Mater
need of specialized grinding wheels with complicated profile Process Technol 121(2):217–225. https://doi.org/10.1016/S0924-
and hence reduce the cost of the production as well. 0136(01)01256-0
9. Chen C, Lin R (2001) A study of manufacturing models for ball-
end type rotating cutters with constant pitch helical grooves. Int J
Authors’ contributions All the authors have taken equal part in
Adv Manuf Technol 18(3):157–167. https://doi.org/10.1007/
performing the research and are sequenced their names in consent with
s001700170
each other. In this research,
10. Chen C, Wang F, Chang P, Hwang J, Chen W (2006) A precision
• A simplified parametric profile of the grinding-wheel is constructed
design and NC manufacturing model for concave-arc ball-end cut-
using line segments and circular arcs. The equation of the wheel swept-
ters. Int J Adv Manuf Technol 31(3):283–296. https://doi.org/10.
surface in five-axis grinding is derived.
1007/s00170-005-0186-7
• Subjected to the flute profile design, the profile parameters of the
11. Kim YH, Ko SL (2002) Development of design and manufacturing
grinding wheel, its relative location, and orientation with respect to the
technology for end mills in machining hardened steel. J Mater
end-mill cutter are optimized, ensuring a specified normal rake angle.
Process Technol 130-131:653–661. https://doi.org/10.1016/
• Validation of the newly developed method has been performed using
S0924-0136(02)00728-8
the CAD simulation, two virtually ground flutes are measured and com-
12. Puig A, Perez-Vidal L, Tost D (2003) 3D simulation of tool ma-
pared with the given specifications.
chining. Comput Graph 27:99–106. https://doi.org/10.1016/S0097-
Grinding of end-mill cutter flutes are often achieved through the in-
8493(02)00248-0
verse method, in which a free-form grinding wheel is first determined and
13. Feng X, Bin H (2003) CNC rake grinding for a taper ball-end mill
manufactured, the grinding wheel is then used to accurately generate the
with a torus-shaped grinding-wheel. Int J Adv Manuf Technol
flutes; however, such free-form grinding wheels are very difficult and
21(8):549–555. https://doi.org/10.1007/s00170-002-1298-y
expensive to manufacture. Moreover, this method neither generates the
14. Chen WY, Chang PC, Liang SD, Chen WF (2005) A study of
rake face with the defined normal rake angle accurately nor generates the
design and manufacturing models for circular-arc ball-end milling
precise side-cutting edges on the end-mill cutters. To solve this issue, a
cutters. J Mater Process Technol 161(3):467–477. https://doi.org/
simple geometric optimization approach is adopted for the multi-axis
10.1016/j.jmatprotec.2004.07.086
CNC grinding of the end-mill flutes.
This new approach can determine the non-standard grinding wheel 15. Hsieh JM, Tsai YC (2005) Geometric modeling and grinder design
that can be economically produced or dressed to accurately grind the for toroid-cone shaped cutters. Int J Adv Manuf Technol 29(9-10):
end-mill cutters using the five-axis CNC grinding process. 912–921. https://doi.org/10.1007/s00170-005-2613-1
16. Hsieh JM (2008) Manufacturing models for design and NC grind-
ing of truncated-cone ball-end cutters. Int J Adv Manuf Technol
Compliance with ethical standards 35(11-12):1124–1135. https://doi.org/10.1007/s00170-006-0794-x
17. Kim JH, Park JW, Ko TJ (2008) End mill design and machining via
Conflict of interest All the authors jointly worked together and contrib- cutting simulation. Comput Aided Des 40(3):324–333. https://doi.
uted in the research and there is no conflict of interest applicable to this org/10.1016/j.cad.2007.11.005
research or publication of it. 18. Chen F, Bin H (2009) A novel CNC grinding method for the rake
face of a taper ball-end mill with a CBN spherical grinding-wheel.
Int J Adv Manuf Technol 41(9):846–857. https://doi.org/10.1007/
Availability of data and material Authors of this publication confirm
s00170-008-1554-x
that the data supporting the findings of this study are available as its
supplementary materials. 19. Lei R, Shilong W, Lili Y, Shouli S (2016) An accurate method for
five-axis flute grinding in cylindrical end-mills using standard 1V1/
1A1 grinding wheels. Precis Eng 43:387–394
20. Lei R, Shilong W, Lili Y, Shouli S (2017) A generalized and effi-
cient approach to accurate five-axis flute grinding of cylindrical
References end-mills. Journal of Manufacturing Science and Engineering.
MANU-16-1560. https://doi.org/10.1115/1.4037420
21. Van-Hien N, Sung-lim K (2016) A new method for determination
1. Smith GT (2008) Cutting tool technology: industrial handbook. of wheel location in machining helical flute of end mill. Journal of
Springer-Verlag, London Limited Manufacturing Science and Engineering; MANU-15-1282. https://
2. Tandon P, Gupta P, Dhande SG (2008) Geometric modeling of doi.org/10.1115/1.4033232
fluted cutters. J Comput Inf Sci Eng 8(2):1–15 22. Xin QQ, Wang TY, Yu ZQ, Hu HY (2018) Grinding process of ball
3. Tandon P, Khan MR (2009) Three dimensional modeling and finite end milling cutter flank. Adv Mater Manuf Technol III 764:383–
element simulation of a generic end mill. Comput Aided Des 41(2): 390. https://doi.org/10.4028/www.scientific.net/KEM.764.383
106–114 23. Han L, Cheng X, Jiang L, Li R, Ding G, Qin S (2017) Research on
4. Ko SL (1994) Geometrical analysis of helical flute grinding and parametric modeling and grinding methods of bottom edge of
application to end mill. Transactions of NAMRI/SME 22:165–172 toroid-shaped end-milling cutter. 233(1): 31-43. https://doi.org/10.
5. Ren BY, Tang YY, Chen CK (2001) The general geometrical 1177/0954405417717547
models of the design and 2-axis NC machining of a helical end- 24. Rababah M, Chen ZC (2013) An automated and accurate CNC
mill with constant pitch. J Mater Process Technol 115(3):265–270 programming approach to five-axis flute Grinding of Cylindrical
 Int J Adv Manuf Technol

End-Mills using the Direct Method. J Manuf Sci Eng 135(1): Publisher’s note Springer Nature remains neutral with regard to jurisdic-
011011. https://doi.org/10.1115/1.4023271 tional claims in published maps and institutional affiliations.
25. Rababah M, Almagableh A, Aljarrah M (2016) Five-axis rake face
grinding of end-mills with circular-arc generators. Int J Interact Des
Manuf 11(1):93–101