A study of design and manufacturing models for circular-arc ball-end milling cutters

The paper presents a systematic manufacturing model for producing the circular-arc ball-end milling (CABEM) cutter. Having first defined the helical angle as the angle between the cutting edge and the axis of rotation of the cutter, the geometric shapes of helical grooves and cutting edge profiles are analytically derived. The feed speed of the grinding wheel in the radial direction is modified according to the cross-section of the groove that passes through the centre of the cutter sphere. The models that are used to calculate the actually obtained groove, and the method of computer simulation are also included. To further enhance the accuracy of the mathematical models, a compensatory machining process, which eliminates residual profile on the revolving surface, is also presented.