Process simulation for five-axis grinding machining using an analytical method

Abstract

In order to promote manufacturing quality for sculptured surfaces, ultra-precision grinding has been used more and more widely in the fields such as aerospace and mould, etc. However, as a key aspect technology, the five-axis grinding simulation has not been paid enough attentions based on the published achievements. This paper presents an analytical method which could compute the wheel-swept surfaces based on the geometrical modelling of the machining process. Considering the tool path in the five-axis machining process, the normal and the velocity vectors for an arbitrary point on the wheel surface are computed firstly. Using the envelope theory, the point on the wheel’s surface as well as on the envelope surface can be calculated. For an arbitrary wheel’s position, the generating line of the envelope surface is obtained using fitting theory when all the sample points are known. Therefore, the sweep-surface can be gained when all the generating curves along the tool path are fitted. Finally, two examples and an example are conducted to verify the theory and the results show that the method can calculate the envelope surface with high efficiency.