Advanced Techniques of Developing High-Performance Cutters through Integration of Cutter Surface Formulation, Programming for Multi-Axis CNC Grinding, and Cutter Performance Evaluation

铣刀，如球/环形/平面端铣刀、铰刀和镗刀等，钻削刀具对加工效率、零件精度和表面光洁度以及加工成本至关重要。 虽然切削工具在工业应用中有着悠久的历史，但即使是现在，切削工具也是由工程师以传统的方式设计的-通过实验进行试错。 随着越来越多的新型金属材料在工业中的应用，需要开发新的刀具，而不是使用传统的刀具。 不幸的是，传统的方法严重依赖于设计师的经验，而且成本很高，时间很长。 尽管存在技术障碍，但工业上迫切需要开发高性能刀具的新技术。 基于申请人在CAD和CNC加工方面的专业知识以及他以前对刀具设计和制造的研究，他提出了一个新的先进研究计划，包括三个主题：（1）用指定的参数制定复杂的刀具表面并生成用于这些表面的多轴CNC磨削的轮路径，（2）端铣刀和钻槽设计和优化，（3）刀具磨损机理模型研究。 虽然目前开发刀具的技术还远远没有达到预期的效果，但这项研究可以显着推进该技术，并使刀具和加工行业受益。

Milling cutters, such as ball/toroid/flat end-mills, reamers, and boring tools, etc., and drilling cutters are crucial to machining efficiency, part accuracy and surface finish, and tooling costs. Although cutting tools have a long history of industrial application, cutting tools even now are designed by engineers in the conventional way – trial-and-error with experiments. With more and more new metal materials adopted in industry, new cutters should be developed, instead of using conventional cutters. Unfortunately, the conventional way heavily depends on the designers’ experience, and it is quite costly and long. Despite of the technical barriers, new techniques of developing high-performance cutters are urgent needed in industry. Based on the applicant’s expertise on CAD and CNC machining and his previous research on cutter design and manufacturing, he proposes a new and advanced research program including three topics: (1) formulating complex cutter surfaces with the specified parameters and generating wheel paths for multi-axis CNC grinding of these surfaces, (2) end-mill and drill flute design and optimization, and (3) investigation of a mechanistic model of tool wear. Although the current technique of developing cutters is far from desired, this proposed research can significantly advance the technique and benefit the tooling and machining industry.