Research On Design And Manufacturing Of Solid Carbide Ball End Mill Of “Shape-Performance-Application” Integration

The car is one of the most important transportation tools, and the consumers require customized car products with their growing living standard. The car manufacturers update the automotive appearance with faster and faster speed, which causes the updating of car cover mould. Therefore, the machining efficiency of car cover mould plays a key role in renewing cycle of car appearance, where cutting tool technology is very important for mould manufacturing. Towards raising the machining efficiency, the dedicated cutting tools are used for the different machining features on the mould, which is called as tool specialization. Under that trend, the number of tool types is raised, and the batch of per type tool is decreased. Therefore, it is very important for achieving the tool specialization to raise accurateness, flexibility and adaptability of tool design and manufacturing.Towards raising the accurateness, flexibility and adaptability of tool design and manufacturing, this thesis analyses the key factors and their relationships of tool shape(S), cutting performance(P) and tool application requirement(A) in cutting tool design, as well as the factors related to tool grinding quality, accuracy and flexibility. Then in order to transfer the data precisely, the tool design features and tool machining features are developed. Based on the analysis above, this dissertation presents cutting tool “S-P-A” integrated design method and distributed manufacturing approach.System architecture and tool models are the two keys in the demonstrating of the method of cutting tool “S-P-A” integrated design. On the one hand, considering the complex characteristic of the system structure of the method, IDEF0 modelling approach is used to build the multi-layer architecture. In the system, cutting tool “S”, “P” and “A” are the three key modules. Based the architecture, the software implementation is also presented. On the other hand, the geometrical models of chamfered ball end mill are proposed, e.g. cutting edge, chamfered face and its grinding track, rake face, first flank face.Targeting the method of distributed tool manufacturing, the thesis presents the architecture of tool manufacturing system and mathematic models related to tool manufacturing. On the one hand, distributed process planning and Function Block(FB) are applied in the tool manufacturing, and then architecture of the system is mapped. Also, the FBs for every tool manufacturing features are designed, and the flowchart of FBs is draws for the tool. On the other hand, in order to generate the point data of grinding, the models of centre track and position of grinding wheel are established, as well as the methods of grinding track discrete.In order to validate the method of cutting tool “S-P-A” integrated design and distributed tool manufacturing approach, the hardened steel mould with multihardness jointing is taken as the machining feature for which tool design and manufacturing are carried out. Based on process of tool “S-P-A” integrated design are proposed, the ball end mill is design for the machining feature. Then according to the models related to tool grinding, the tool prototypes are machined in the Saacke UWIF grinding tool. Finally, the performance of designed tool is better in comparison with the common tool from the result of the experiment.