The present invention relates to a machine shop grinding tool, and in particular to a bench-top end mill grinding center.
Machine shops universally use end mills in computerized milling machines, e.g. computer numerical control (CNC) milling machines, as a cutting tool for all industrial milling applications, such as profile milling, tracer milling, face milling, and plunging. End mills are categorizated by the number of flutes, by the helix angle, by the material; and by the coating material. Over the last two decades CNC milling machines have increased in speed ten fold, whereby the milling cutters now commonly have exotic coatings and/or are made from solid carbide to improve part cycle time and tool life. Moreover, contemporary tools have more aggressive geometry, are more expensive than regular high-speed steel cutters, and are more difficult to recondition.
Even with good equipment, an experienced technician with a keen eye and magnification is required to recondition end mill cutting tools. Careless reconditioning can result in the clearance angles and the flute geometry to be disproportionately maintained. Furthermore, diameter change issues, such as friction and chip evacuation, will be affected causing a reduction in performance.
The performance end mill type milling cutters currently in widespread use in the mainstream production job shop market are more expensive, made from the most premium grades of solid carbide, and are rotating at spindle speeds much higher than ever before, requiring different structural and performance geometry with high finish and accuracy. A high-level of attention must be given to tool feature, tolerance and finish or they will not cut and extract material with tolerable heat and friction at the higher speeds.
Cemented tungsten carbide tools are a composition of tungsten carbide powder with a varying degree of cobalt binder, which breaks down over time due to cycling of load moments causing the leaching of the cobalt away from the carbide powder, thereby degrading the integrity of the substrate locally. As a result, the area of the end mill cutter tool that was under the highest loads should no be returned to service as the material has been altered at the inter-granular level. In addition, current protocols, such as ISO9000, prescribe that if an end mill cutter diameter is altered requiring an edit to the program speeds, feeds and offsets used to run the part, the part is required to be re-inspected prior to commencing production. Re-inspection slows down the manufacturing/shop process and is therefore unwelcome, considering the end mill cutter tool that has just been returned to service will not perform as well as or as long as a new one.
The reality of small carbide milling cutters is that the area of high exposure to heat, load and friction is a “throw away” or for one time use, due to material breakdown. As a general rule, tools that can be ground back into areas free of substrate breakdown can be effectively re-sharpened with shop support equipment, but, in general, shops do not use reconditioned tools because they are usually small and as such there are just too many issues, which affect the true cost of doing so, only to be marginally effective.
High loads combined with more radical tool geometry, and stringent concentricity requirements mean new carbide end-mill cutter tools, as a rule, must be held more accurately with greater force during the machining process than their high-speed steel predecessors. Carbide end-mill tools are also used differently in shops today, wherein faces on parts are often machined with stub flute tools having a solid reduced necks giving greater stability at higher material removal rates, although long flutes are still the method of choice for finishing larger faces with high finish.
To sharpen carbide end-mill cutters, the end is cut off to get into new unused material, while watching to ensure the tool does not over heat. Furthermore, special care must be taken to ensure: the diameter does not change; a flat or “notch” is produced, so that the tool can be held well in a side lock tool holder; a reduced neck is ground; a ball nose is resharpened; and a corner rad “bull nose” champher or blend radius is produced.
The principal attraction of conventional bench top sharpeners, such as those produced by Cuttermaster®, Darex®, and Chevalier®, has been cost, and a perceived ease of use. Moreover, they have been servicing a market in which High Speed Steel (HSS) tools were being used in an environment with mostly conventional or CNC machines having spindles designed to operate below 5000 rpm that would tolerate a reground cutter, i.e. rotational speeds and part feeds were lower, with less pressure on part cycle.
An object of the present invention is to overcome the shortcomings of the prior art by providing a tool grinder able to easily reproduce cutter end geometry within tenths of thousandths, without heat damage to the tool.
Accordingly, the present invention relates to a rotating cutting tool sharpening device comprising a main base, a tool spindle assembly, and a motor tower assembly.
The tool spindle assembly supports a cutting tool holder during processing of a rotating cutting tool, and enables reciprocation along first and second perpendicular axes parallel to the main base and rotation about a vertical axis extending perpendicular to the main base; and
The motor tower assembly including: a frame reciprocatable on the main base and rotatable about a vertical axis on the main base, and a motor reciprocatable vertically on the frame, and rotatable about a horizontal axis on the frame, wherein the motor is for rotating one of a plurality of interchangeable modifying tools;
Accordingly, the motor is positionable at an angle to the horizontal and perpendicular to the tool spindle assembly with an end face of one of the modifying tools perpendicular to the cutting tool in a first position, and parallel to the tool spindle assembly with the end face of the modifying tool facing the cutting tool in a second position.
Another aspect of the invention relates to a rotating cutting tool sharpening device comprising:
a main base;
a tool spindle assembly for holding a cutting tool for processing comprising:
a motor tower assembly comprising:
whereby the motor is positionable at an angle to the horizontal and perpendicular to the tool spindle with an end face of one of the modifying tools perpendicular the cutting tool in a first position, and parallel to the tool spindle with the end face of the modifying tool facing the cutting tool in a second position.
The invention will be described in greater detail with reference to the accompanying drawings which represent preferred embodiments thereof, wherein:
With reference to
Primary features of the end-mill grinding tool include a ground stone base 1 for rigidity and harmonic stability (absorbs resonant energy), and multi-axis positioning tool spindle assembly 2 and a motor tower 3. The tool spindle assembly 2 combines conventional linear air bearing capability with radius grinding, wheel dressing, and independent feeds in two axis. The six axis, variable-speed, reversing motor tower 3 enables a universal approach to the tool being ground and variable heat input needed to control integrity of carbide tools during sharpening.
The end mill grinding tool of the present invention is comprised of the L-shaped ground stone base 1, with a first channel for slideably receiving the tool spindle 2, and a second channel for slideably receiving the motor tower 3. Channel locks 50 are provided for placing in first and second substantially perpendicular channels 51 and 52 for locking the tool spindle 2 and the motor tower 3 in place and in particular in relative position.
The tool spindle assembly 2 includes a main carriage 4, which reciprocates in a first direction, e.g. along the x axis, in the second channel 52 by rotation of a first spindle 5. The tool spindle assembly also includes a pivot base 6 pivotally mounted on the main carriage; an X-Y axis carriage 7, which reciprocates laterally, e.g. in the y-axis, by rotation of a second spindle 8; a tool spindle carriage 10, which slides on the X-Y carriage 7 by rotation of a third spindle 9, and a tool spindle 11 extending through the tool spindle carriage 10. The main carriage 4 is the primary base plate and foundation for the tool spindle assembly 2, and is mounted through to the base 1 and may travel in the second channel 52. The pivot base 6, which is a match fit on the flat surface of the main carriage 4, acts as a pivot point (360° about a tool rest pin 12) for radial work and includes laterally extending dovetail rails to accommodate the dovetail grooves in the X-Y axis carriage 7 for linear Y-axis movement. The X-Y axis carriage 7 travels along the Y axis perpendicular to the longitudinal axis of the tool spindle 11 on the pivot base 6 using spindle 8. The tool spindle carriage 10 slides along the top of the X-Y axis carriage 7 utilizing a third spindle 9. The tool spindle 11, which slides thru and rotates in a set of ground steel bearing sleeves 13 mounted in the tool spindle carriage 10, accommodates a 5c type collet, which is closed by a draw tube mounted to a rotating handle 16 on the opposite end. A slotted indexing collar 17 with a spring return pin 18 allows for rotational positioning. The tool spindle carriage assembly 10 has a sliding center tailstock mount for receiving end mill tools, and securely holding even long neck end mill tools during grinding. The axis of rotation of the pivot base 6 is remote from the X-Y carriage 7 and tool spindle carriage 10, whereby the tool spindle 11 traces an arc around the axis of the tool rest pin 12, and the end mill tool 31 remains pointed at or extending through the axis of rotation.
The motor tower 3 is a stable multi-axis positioning device mounted on a tower base 21, which slides in the second channel 52 (Y axis) with the aid of tower spindle 22. The motor tower 3 includes: a rotating base 23, which can rotate around 360° on the tower base 21 (θZ axis); a vertical frame 24; a motor angle bracket plate 25, which secures a motor 26 to the vertical frame 24; a motor pivot assembly 27, which enables the motor 26 to be rotated 360° about an X or a Y axis (θX & θY axes); a motor radial carriage 28, which enables the motor 26 to slide up and down; and a flying lead-screw spindle assembly 29 for controlling reciprocating motion of the motor carriage 28 in the Z axis. Fasteners 32 secure the motor angle bracket plate 25 to the motor radial carriage 28 while snuggly sandwiching the vertical legs of the vertical frame 24 therebetween, enabling the motor radial carriage 28 to reciprocate up and down the vertical frame 24. Locking screws 33 enable the motor radial carriage 28 to be locked in position on the vertical frame 24. A main locking nut 34 provides an axis of rotation of the motor 26, and enables the position of the motor 26 to be adjusted to any angle (360°).
The motor tower assembly 3 principally reciprocates in the second channel 52 of the base 1, i.e. along the Y axis, and may be rotated about a vertical axis (θZ axis) perpendicular to the base 1. The motor 26 may be fully rotated (θX & θY axes) to bring different modifying tools, e.g. grinding or cutting wheels 30 and or other approaches, to bear against a tool 31 positioned in tool spindle carriage 10. The unique flying lead screw 29 raises and lowers the radial motor carriage 28, and moves in a combination horizontal and vertical direction to temporarily move the wheel 30 off the tool 31, while indexing the tool 31 during the grinding process. A slot 36, (
The outer periphery of the milling cutter tool 31 is the part that does the cutting, while the flute face handles the chip evacuation. Accordingly, an end mill grinder must be able to address both the outer periphery and the flute faces in a way that enables accurate profile generation and surface finish without damaging the grinding wheel 30 or overheating the tool material.
In a basic configuration the end mill 31 rests on the tool rest pin 12, giving the end mill tool 31 a fixed relationship with the grinding wheel 30 during processing, e.g. a flute outer diameter grinding process. The end mill tool 31 is then adjusted to the tool rest pin 12 instead of the tool rest pin 12 being brought to the end mill tool 31. Setting the end mill tool 31 square and level with the tool rest pin 12 at tool center height, and then tilting the grinding wheel 30 to the desired angle is the only way one can guarantee proper dialed in clearance angles.
The arrangement for corner and end radius grinding, common in mold and aerospace work, is illustrated in
In
A flaw in the design of conventional end mill grinding devices requires that the grinding wheels must be constantly re-profiled and re-dressed to a sharp edge in order to get a good center cutting grind. Composite diamond and CBN wheels cannot be readily re-shaped without elaborate wheel grinding equipment, which is rarely available in a machine shop. The prevention of damage to the grinding wheels and preservation of their shape is necessary to the too re-sharpening process.
An advantage of the present invention is the ability to true, contour and dress the grinding wheels 30 without the use of separate contrivances common on conventional machines to service grinding wheels, which normally requires the breaking of a set up. Proper grinding wheels, correctly maintained are necessary in order to achieve good results in any grinding process.
Normal end mill use causes wear on the end of the end mill tool 30 and or chipping and pitting of the corners thereof. When carbide tools are used in a contemporary reduced-neck, high-speed machining cycle the end is the part of the tool that wears out. In order to get a worn tool back into the production process, the tired end material should be cut off and the tool tip recreated in sound material. As illustrated in
Flat generation for side lock holders is illustrated in
Rotary cutting tools must be stable under high speed and load in order to reliably hold tolerances and leave good finishes. For high speed machining, the flute length of the end mill tool 31 can be reduced leaving longer solid necks to obtain stability. The shank of the end mill tool 31 is the portion of the tool in the holder. With reference to
The present invention claims priority from U.S. Patent Application No. 60/867,115 filed Nov. 23, 2006, which is incorporated herein by reference.
Number | Name | Date | Kind |
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2420170 | Erikson et al. | May 1947 | A |
3030744 | Mueller | Apr 1962 | A |
4115956 | Huffman | Sep 1978 | A |
4134235 | Maharidge | Jan 1979 | A |
4461121 | Motzer et al. | Jul 1984 | A |
4597226 | Jewett, Sr. | Jul 1986 | A |
Number | Date | Country | |
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60867115 | Nov 2006 | US |