Specific Material Removal Rate Calculation in Five-Axis Grinding

Specific material removal rate (MRR) $q′$ was calculated for five-axis grinding in a virtual machining simulation environment (VMSE). The axis-symmetric tool rotational profile was arc-length parameterized. The twisted grazing curve due to the concurrent translation and rotation in every move was modeled through an exact velocity field and areal MRR density $q″$⁠, positive in the front of the grazing curve on the tool surface. Variation of $q′$ and equivalent chip thickness $h$ within the instantaneous engagement contour were deduced from $q″$⁠. Illustrative results with a five-axis impeller blade finishing simulation are shown. The results were benchmarked against an average $q′$ calculated from the instantaneous MRR from the VMSE. As a function of time, maximum chip thickness $hmax$ within the extents of contact along the tool profile in every move showed more isolated peaks than corresponding $qmax′$⁠. Maximum cumulative material removed per unit length $Qmax′$ along the tool profile from all the moves was calculated to predict axial location of maximum risk of cutter degradation. $Qmax′$ and $hmax$ are useful metrics for tool path diagnosis and tool wear analysis.