A precision tool model for concave cone-end milling cutters

The paper presents a comprehensive manufacturing model that can be used to produce a concave cone-end milling (CCEM) cutter on a two-axis NC machine. A CCEM cutter possesses many distinct features that are superior in many cases to the traditional flat-end milling cutter for producing parts with multiple sculptured surfaces. Based upon the given design parameters and criteria, the equation of the helical flute groove and the curve of the cutting edge at the end of the helical flute are derived and presented. By using an inverse problem-solving technique, the sectional profile of the grinding wheel, the tool compensation for machining, and the feedrate of both NC axes are consequently obtained. The design results are compared with the measured data obtained from the NC produced CCEM cutter. The satisfactory comparative verification indicates that the tool design and manufacturing model presented in this paper is theoretically sound and it can be automated easily. The proposed method is widely applicable for the mass production of various high-efficiency milling cutters.