The research project “Manufacturing of Carbide Cutting Tools by Continuous Generating Grinding” (DE447/236-1) represents the third effort aimed at systematically transferring continuous generating grinding to tool manufacturing. While previous projects successfully applied the process, originally known from gear manufacturing, to HSS milling cutters with uniform pitch, the focus of this project was on extending the approach to more industrially relevant carbide tools.
A key aspect of the work was the further development of the design methodology. This was expanded to enable the production of cutting tools with non-uniform pitch as well as tools featuring individually defined cutting edge geometries. The design of the grinding worm is initially carried out through a simulation-based analysis using the in-house software CutS. Building on this, a MATLAB-based computational approach is applied, which relies on the Newton–Raphson method to determine the precise geometry of the grinding worm. This combination of simulation and numerical calculation enabled a precise and flexible tool design.
In addition to the geometric design, the grinding process itself was comprehensively analyzed. Particular focus was placed on the influence of the grinding wheel bond, the dressing process, as well as suitable process and shifting strategies. The results show that the productivity of continuous generating grinding is significantly influenced by the cutting speed and the continuous shift speed. Targeted adjustment of these parameters allows for a substantial increase in process efficiency.
To evaluate industrial applicability, the manufactured milling tools were also compared with conventionally ground tools. The results indicate that the performance and tool life of the generating ground tools are comparable to those of conventionally manufactured tools. This highlights the potential of continuous generating grinding as an economical alternative in tool manufacturing.
Overall, the project results provide a solid foundation for the further industrial implementation of the process and demonstrate that continuous generating grinding is a highly promising approach, particularly for the flexible and productive manufacturing of complex carbide cutting tools. Building on these findings, a follow-up research project has already been proposed. This project will focus on the targeted analysis of the thermomechanical load acting on the grinding worm. The goal is to use these insights to further optimize the design of the grinding worm and thereby improve process stability, tool life, and overall efficiency.
Contact:
For further information, please contact Niklas Gärtner on +49 511 762 19420 or via email at gaertner@ifw.uni-hannover.de.
