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6-axis CNC Blade Grinder

6-axis CNC Blade Grinder. Taking blades to Finish Size and Surface Finish. Generic 6-Axis CNC Grinder. Layout for a 6-axis grinder (Artist’s concept). X, Y, Z and A in Table. B and C in “spindle”. Barrel Tool. Tool Record Continuation. Orientation to Part.

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6-axis CNC Blade Grinder

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  1. 6-axis CNC Blade Grinder Taking blades to Finish Size and Surface Finish

  2. Generic 6-Axis CNC Grinder • Layout for a 6-axis grinder (Artist’s concept). • X, Y, Z and A in Table. • B and C in “spindle”.

  3. Barrel Tool

  4. Tool Record Continuation

  5. Orientation to Part • Barrel is twisted around axis of Spindle – C-axis • Barrel is held so that contact point is normal to surface • Axis of Barrel is rotated along Stations.

  6. Grind/Polish Process • A possible method of grinding/polishing is described. • The process consists of taking a blade semi-finished with +.005” scallop and up up +.015” stock per side to finish.

  7. Initial track is roughed at tip of blade. Blade is rough ground to remove scallops and close to finish dimension. Depending on blade, belt and material multiple roughing passes might be required. Initial finish pass is made. Part is probed at one point to determine compensation due to belt. Tool “length” is adjusted and finish pass is made. Process Continued

  8. Continuous 6-axis operation with 5-axis tool length compensation is required. Sustained 6-axis block execution time of approximately 2 milliseconds with 5-axis tool length compensation. Probing of part is desireable. Ability to utilize subprograms. Ability to adjust tool length with-in part program. CNC capability

  9. Grinding/polishing operation is controlled by a master program. The master program invokes the following programs: Tip end slot grinding Blade roughing/semi-finish. Program is invoked with varying tool length offsets based on number of passes needed. Blade finish program. Point probe. Probing of point is used to make adjustment of tool length based on barrel dernier, belt grit, and other process related conditions. Blade finish program re-run with tool length adjustment. Part Program Structure

  10. Open Track at Tip FILENAME 132D3733R.NF2 CREATED 4-MAR-93 19:53:54 PART NO: 132D3733R.NF 3. 4.5 120 5248 1 3 2 1 ; OPERATIONAL INPUT PART NO. 132D3733 ROUGH TIP-R ;****************************************** ; BEGIN OPERATIONAL INPUT 1.5 1. 150. 150. 150. 121 98 200 1. GRIND SURFACE USING A 20.000" BARREL ; 122 RECORD -13.3301 107.267 122 90 31 5.0 -5.0 126 3 1 2 .0006 .0006 123 ; LINE CUT FOR TIP 1. .01 3. 95 302 -303 -304 170 2

  11. Rough Grind Blade FILENAME 132D3733M.NF2 CREATED 4-MAR-93 19:53:54 PART NO: 132D3733M.NF 3. 4.5 120 5248 1 3 2 1 ; OPERATION INPUT PART NO 132D3733 ;****************************************** ; BEGIN OPERATIONAL INPUT 1.5 1. 150. 150. 150. 121 98 200 .75 20. GRIND SURFACE USING A 20.000" BARREL ROUGH GRINDING PASSES -13.3301 107.267 122 90 31 5.0 -5.0 126 3 1 2 .2 .0006 .0006 123 .01 3. 96 -301 404 1 1. .6 -302 304 303 .75 .005 .005 123 170 2

  12. Inspection Program FILENAME 132D3733I.NF2 CREATED 4-MAR-93 19:53:54 PART NO: 132D3733I.NF 3. 4.5 120 5248 1 3 2 1 .125 10. 10. 10. 121 75 .25 20. -.05 .05 PROBE SURFACE -13.3301 107.267 122 5.0 -5.0 126 3 1 2 1. 0. 0. 90 1 2 1 1. 2.5 104 302 15 15 170 2

  13. Finish/Polish Blade FILENAME 132D3733A.NF2 CREATED 4-MAR-93 19:53:54 PART NO: 132D3733A.NF 3. 4.5 120 5248 1 3 2 1 ; OPERATIONAL INPUT PART NO. 132D3733 FINISH-A ;****************************************** ; BEGIN OPERATIONAL INPUT 1.5 1. 150. 150. 150. 121 98 200 .75 20. GRIND SURFACE USING A 20.000" BARREL ; REMAINING FINISH PASSES -13.3301 107.267 122 90 31 5.0 -5.0 126 3 1 2 ; AREA SWEEP FOR FINISH PASS IS 0.125 .2 .0006 .0006 123 .01 3. 96 -301 404 1 1. .125 -302 304 303 170 2

  14. Level-II Capabilities • D-curves may be calculated using the Barrel Tool. The D-curve is calculated in the same manner as any non-Ball End Mill.The reference offset for the D-curve is ½ the diameter of the barrel. • Interactive Level-II plots this tool showing the barrel and some of the belt leading in and out of the barrel. • Program point of tool is center of barrel at outside edge.

  15. Roughing Program

  16. Surface finish is directly related to: Grit of belt Proper coolant flow Machine and CNC performance Hardeness (dernier) of barrel Method of compensating machine for belt condition is CNC dependent. Barrel Radius must be less then minimum concave radius along stations. Diameter must be less than minimum concave diameter along templates. “I” analysis provides information on minimum radii of selected surface. Notes

  17. Stator CNC Ground

  18. CNC Ground Rotor

  19. CNC Ground Rotor

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