Research on CNC Grinding System of Helical Teeth Tool
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This paper presents a study on the CNC grinding method for spiral tooth cutters, focusing on the geometric parameter acquisition of helical cutting edges. The design and development of an economical CNC tool grinding machine control system for sharpening such tools are also discussed. Key technologies are introduced, highlighting how this system improves efficiency and precision in tool sharpening.
1. Introduction
Helical tools, such as cylindrical milling cutters, end mills, and spiral groove reamers, have cutting edges that require regular sharpening. Traditionally, this process is performed manually on a tool grinding machine, relying heavily on the operator’s skill. The operator judges contact between the grinding wheel and the tool based on sparks, manually controlling the feed amount. This manual approach leads to inconsistencies in quality, high labor demands, and low efficiency. To address these issues, this research explores a CNC grinding method tailored for spiral tooth cutters, resulting in the development of a cost-effective, small-scale CNC tool grinder capable of handling unknown parameters.
2. CNC Tool Grinding Machine Drive System
The mechanical drive system of the CNC tool grinding machine includes three main axes: X, Y, and Z. The Y and Z axes control the table’s horizontal and vertical movement, while the X axis controls the grinding head. The C axis is responsible for the rotation of the workpiece (the tool). Manual adjustments allow the grinding head to rotate around the X-axis, enabling precise positioning of the grinding wheel relative to the tool.
3. Control System Hardware Structure
The control system uses a microcontroller 8031 as its central processing unit. Program storage is managed via the P0 port connected to a 32 KB EPROM (27256), while data is stored using a 2 KB RAM (6116) connected to the same port. The P2 port handles address decoding, interfacing with LED displays, I/O chips (8155, 8255), memory (6116), and latches (273). The P1 port connects to the manual control circuit for stepper motors, which receive pulse signals from the P0 port through the latch. The 8155 chip manages input/output functions, including start/pause buttons, mode selection, and keyboard interface.
4. Helical Tooth Geometry Measurement
Accurate measurement of helical teeth geometry is essential before grinding. Since the helix angle and lead are often unknown, the tool must be measured first. By unrolling the helical surface into a straight line, axial and circumferential feeds can be related. A measuring head is mounted on the grinding head, forming a closed circuit during measurement. The system records steps taken by the tool in both linear and rotational directions, calculating the necessary coordinates for accurate grinding.
To prevent overtravel errors in the C-axis, the step size is minimized, and the motor's step angle is reduced. Increasing the Z-direction measurement length also helps improve accuracy, reducing the impact of any minor errors in rotation.
5. Control System Software
The software is structured in modular form, with different modes depending on user input. The main operating modes include:
- **Parameter Input Mode**: Users enter key parameters like number of teeth, feed length, and grinding allowance.
- **Measurement Mode**: The system uses manual controls to position the tool and measure critical dimensions.
- **Tool Setting Mode**: Adjusts the grinding wheel to match the tool’s geometry, ensuring consistent sharpening.
- **Automatic Mode**: Performs multi-cycle sharpening, ensuring uniformity across all teeth and improving efficiency.
6. Conclusion
The implementation of a CNC-based system for spiral tooth sharpening significantly enhances precision and consistency compared to manual methods. It reduces the impact of temperature variations, ensures stable quality, and increases productivity. With automated measurement and sharpening, it simplifies the process, making it more efficient and reliable. This system is particularly effective for equally divided spiral tooth cutters, offering a practical solution for modern machining environments.
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