Determination of workpiece profile and influence of singular point in helical grooving

Due to the screw motion between the grinding wheel and workpiece in helical groove machining, the determination of the generated helical groove profile in a workpiece is very complicated. The profile of helical groove can be obtained by using the common contact line of the helical groove and wheel surface. The influence of singular points in a wheel profile on a helical profile is analysed. The condition used to solve the equation of tangency is discussed. Software for design, simulation and manufacturing of the end mill as well as for solving the problem of singular points is developed. The results of simulation and experiments are compared as a verification of the suggested model.