NC data generation for 6-axis machine tools to produce a helical drill

This study presents a design methodology for grinding a specific helical drill on a CNC 6-axis grinding machine. The proposed methodology comprises three steps: (1) deriving a mathematical model of the helical drill, (2) establishing the ability matrix of the multi-axis grinding machine according to Denavit-Hartenberg (D-H) notation, and (3) constructing configuration matrices to express the required grinding wheel positions and orientations while machining the flute and flank surfaces of the drill. The NC data for the motion values of each axis are obtained by equating the corresponding elements of the CNC ability matrix and the configuration matrices of the grinding wheel. To verify the proposed methodology, a designed helical drill is machined on a 6-axis CNC tool-grinding machine. The methodology presented in this study integrates the drill design and manufacturing activities, thereby making possible the implementation of a more flexible, automatic, cost efficient and controllable design and production process.