j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 1 ( 2 0 0 8 ) 618–622

journal homepage: www.elsevier.com/locate/jmatprotec

Planning and analysis of grinding processes for end

mills of cemented tungsten carbide

Jenn-Yih Chen a,∗ , Bean-Yin Lee a , Chi-Hsiang Chen b

a Department of Mechanical and Computer-Aided Engineering, National Formosa University, Taiwan
b Institute of Mechanical and Electro-Mechanical Engineering, National Formosa University, Taiwan

a r t i c l e i n f o a b s t r a c t

Keywords: End mills are widely employed in cutting applications, but there is lack of standard grinding
End mill process. Thus the main purpose of this paper is to plan the grinding processes of end mills,
Grinding process including approach and retract sequence of each axis, and grinding parameters, etc. A tool
Approach and retract sequence grinding CAM system was applied to set appropriate parameters in order to find out the
optimal approach and retract distance, and the sequence. In the experiments, a five-axis
CNC tool grinder was utilized to grind a square end mill and a ball nose end mill with two
flutes to verify the efficiency for the saving of time. Experimental results show that the
efficiency was improved approximately up to 40% by the approach and retract time, and
the overall machining time, 10%. Therefore, the results demonstrated the effectiveness of
the proposed processes for the saving of machining time. They also can be applied to grind
different shapes of cutting tools.
© 2007 Elsevier B.V. All rights reserved.

1. Introduction the uniform, common, and optimal procedures via conven-

Due to rapid developments in the modern cutting technology
(Schulz and Moriwaki, 1992; Schulz and Hock, 1995; Dewes
and Aspinwall, 1997), the demand for all kinds of high pre-
cision cutting tools will relatively increase. The grinding for
cutting edges of tools is known as the most important and
the final procedure of manufacturing. It is also a critical issue
for determining geometry shapes, cutting performance, wear
on the cutting edge, and tool life (Malkin, 1989). In the past,
some different accessories must be mounted on conventional
tool grinders to grind the flute, flat gash, and the relief angle,
etc. This will lead to undesirable degrading of grinding preci-
sion. Most manufacturers acquire precious know-how for tool
grinding. They mainly use trial and error methods which are
laborious and time-consuming, and can not be used as uni-
versal applicable standards. Furthermore, geometry shapes of
cutting edges are quite complex so that it is difficult to obtain
tional tool grinders. Therefore, the grinding processes have
not been standardized yet. It makes a retreat for relative man-
ufacturers for developing this technology. According to the
theoretical analysis or the empirical models, there are vari-
ous types of simulation for grinding processes (Tonshoff et al.,
1992; Badger and Torrance, 2000; Nguyen and Butler, 2005a,b).
However, these are only the kinematic simulation of the grind-
ing processes.
Currently, more detailed and useful know-how of milling
cutters is possessed by some corporations, and it is difficult to
acquire. Moreover, the formalization of CAM human machine
interface of the tool grinding software in market conditions is
not completely suitable for end users. Thus, a five-axis CNC
tool grinder and CAM system were employed to construct
the grinding processes of end mills and obtain the optimal
approach and retract distance, and the sequence. By means
of 3D simulation, the system can grind the correct tools and

∗
Corresponding author. Tel.: +886 5 6315322.
E-mail addresses: jychen@nfu.edu.tw (J.-Y. Chen), leebyin@nfu.edu.tw (B.-Y. Lee), explorer5270@yahoo.com.tw (C.-H. Chen).
0924-0136/$ – see front matter © 2007 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2007.11.214
 j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 1 ( 2 0 0 8 ) 618–622 619

reach the safety machining. It is very flexible and efficient for

tool grinding.

2. Grinding processes planning

2.1. Design procedures of end mills

End mills are generally used in mechanical machining. The

parameters of geometry shapes of end mills are the helix
angle, rake angle, relief angle, clearance angle, and the land,
etc (United State Cutting Tool, 2004). These values are related
to materials of machining, and affect the cutting performance
and tool life. The following are the design procedures of end
mills:

1. Drawing shapes of cutting tools.

2. According to cutting tools, choose the grinding process and
the sections which would be ground.
3. Planning the approach and retract sequence of grinding
process.
4. Using the mathematical model of space geometry to gen-
erate the NC program.
5. Executing 3D simulation to confirm the accuracy of tool
design and programming codes.
6. Applying a five-axis CNC tool grinder to grind cutting tools.
2.2. Grinding processes of a radial rake angle
Radial rake angles are varied according to tool functions and
different grinding methods. The grinding method of a radial
rake angle of milling cutters is divided into the flute and the
shear flute. Fig. 1 shows the definition of each axis of a five-axis
CNC tool grinder. With the tool grinder to grind a radial helix
rake angle, the NC path is generated according to the land,
helix angle, rake angle, and the core diameter of an end mill.
The grinding sequence is: X, C, and A axes start at the same
time first. Y-axis moves forward. Then, the rotation degree of
A-axis is the helix angle which we want. X and Y axes shift to
the grinding face of a wheel and the cutting face of a milling
cutter. Finally, Z-axis shifts to the approach distance of grind-
ing. X, Y, and C axes start simultaneously to grind the flute
length. Z-axis moves upward in the vertical direction to make
the wheel exit the groove. X, Y, and C axes return to the starting
point simultaneously. Another flute can be ground according
to the sequence of the above.
Once the tool grinder is utilized to grind a radial rake angle
for shear flutes, the NC path is generated according to the
land, rake angle, and the core diameter of an end mill. The
grinding sequence is: X and C axes start at the same time
Fig. 1 – Definition of each axis of a five-axis CNC tool
grinder.
first. Y-axis moves forward. Then, X and Y axes shift to the
grinding face of a wheel and the cutting face of a milling cut-
ter. Finally, Z-axis shifts to the approach distance of grinding.
X-axis grinds to the bottom. Z-axis moves upward in the ver-
tical direction to make the wheel exit the groove. X and C axes
return to the starting point simultaneously. Another flute can
be ground according to the sequence of the above. Fig. 2 shows
the diagram of grinding the radial rake angle for flutes and
shear flutes.
2.3. Grinding processes of an axial rake angle
Axial rake angles are varied according to tool functions and
different grinding methods. The grinding method of an axial
rake angle of milling cutters is divided into the flat gash and
the curve gash. The flat gash is used on square end mills and
small radius end mills. With the tool grinder to grind an axial
flat gash, the NC path is generated according to the rake angle
and the gash angle of an end mill. The grinding sequence is:
X, C, and A axes start at the same time first. Y-axis moves for-
ward. Then, X and Y axes shift to the grinding face of a wheel
and the cutting face of a milling cutter. Finally, Z-axis shifts to
the approach distance of grinding, and according to the ver-
tical displacement, moving angle, moving distance, and the
backout gash angle to grind the axial rake angle. X, Y, and Z
axes start simultaneously to grind to the bottom. Z-axis moves
upward in the vertical direction to make the wheel exit the
groove. X, Y, and C axes return to the starting point simultane-

Fig. 2 – Diagram of grinding the radial rake angle for (a) flutes and (b) shear flutes.
620 j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 1 ( 2 0 0 8 ) 618–622
Fig. 3 – Diagram of grinding: (a) flat gash and (b) curve gash.
ously. Another flute can be ground according to the sequence
of the above.
Ball nose end mills employ the curve gash to grind blades of
the end face of cutting tools. Once the tool grinder is utilized to
grind an axial curve gash, the NC path is generated according
to the rake angle, gash radius, and the gash helix angle of an
end mill. In general, the gash helix angle is smaller than the
helix angle of flutes. The grinding sequence is: X, C, and A
axes start at the same time first. Y-axis moves forward and
shifts to the grinding face of a wheel and the cutting face of a
milling cutter. Finally, Z-axis shifts to the approach distance of
grinding, and according to the front rake angle, rear rake angle,
and the depth of the groove to grind the axial rake angle. X, Y,
Z, C, and A axes start simultaneously to grind to the bottom. Z-
axis moves upward in the vertical direction to make the wheel
exit the groove. X, Y, A, and C axes return to the starting point
simultaneously. Another flute can be ground according to the
sequence of the above. Fig. 3 shows the diagram of grinding
the flat gash and the curve gash.
2.4. Grinding processes of a relief angle
2.4.1. Flat relief angle
With the grinder to grind the radial and the axial flat relief
angles, the NC path is generated according to the outside
diameter of cutting tools, tilt angle of wheels, relief angle, and
the relief land. The grinding sequence of a radial flat relief
angle is: X, Y, C, and A axes start at the same time, and shift
to the approach distance of grinding face of a wheel and the
cutting face of a milling cutter. There is 1◦ difference between
A-axis and the slope of tool shapes. Then, the rotation degree
of C-axis is the radial relief angle. Finally, Z-axis moves down-
ward to the approach distance. Y-axis shifts to the grinding
face of a wheel and the cutting face of a milling cutter. X, Y,
and C axes start simultaneously to grind the cutting edge from
the base to the end face. Y-axis returns in the horizontal direc-
tion to make the wheel exit the groove. Then, X, Y, and C axes
Fig. 4 – Diagram of grinding: (a) radial flat relief angle and (b) axial flat relief angle.
return to the starting point simultaneously. Another flute can
be ground according to the sequence of the above.
The grinding sequence of an axial flat relief angle is: X, Y,
C, and A axes start at the same time, and shift to the approach
distance of grinding face of a wheel and the cutting face of a
milling cutter. A-axis rotates to the grinding angle that is 90◦
minus the relief angle, and then the rotation degree of C-axis is
90◦ . Finally, Z-axis moves downward to the approach distance.
Y and Z axes start simultaneously to grind from the outside
diameter to the center of the end face of tools. Y-axis returns
in the horizontal direction to make the wheel exit the groove.
Then, Y, Z, and C axes return to the starting point simultane-
ously. Another flute can be ground according to the sequence
of the above. Fig. 4 shows the diagram of grinding the radial
flat relief angle and the axial flat relief angle.
2.4.2. Concave relief angle
Once the tool grinder is used to grind the radial and the axial
concave relief angles, the NC path is generated according to
the outside diameter of cutting tools, tilt angle of wheels, relief
angle, and the relief land. The grinding sequence of a radial
concave relief angle is: X, Y, C, and A axes start at the same
time, and shift to the approach distance of grinding face of a
wheel and the cutting face of a milling cutter. A-axis rotates
to orthogonalize with tool shapes. Z-axis moves downward
to the approach distance. X-axis shifts to the grinding face
of a wheel and the cutting face of a milling cutter. Finally,
X, Y, C, and A axes start simultaneously to grind the cutting
edge from the base to the end face. X-axis returns in the hor-
izontal direction to make the wheel exit the groove. Then, X,
Y, C, and A axes return to the starting point simultaneously.
Another flute can be ground according to the sequence of the
above.
The grinding sequence of an axial concave relief angle is:
X, Y, C, and A axes start at the same time, and shift to the
approach distance of grinding face of a wheel and the cutting
face of a milling cutter. A-axis rotates to orthogonalize with
 j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 1 ( 2 0 0 8 ) 618–622 621

Fig. 5 – Diagram of grinding: (a) radial concave relief angle and (b) axial concave relief angle.

tool shapes. Z-axis moves downward to the approach distance.

X-axis shifts to the grinding face of a wheel and the cutting
face of a milling cutter. Finally, X, Y, C, and A axes start simul-
taneously to grind from blades to the center of the end face
of tools. X-axis returns in the horizontal direction to make
the wheel exit the groove. Then, X, Y, C, and A axes return to
the starting point simultaneously. Another flute can be ground
according to the sequence of the above. Fig. 5 shows the dia-
gram of grinding the radial concave relief angle and the axial
concave relief angle.
Fig. 6 – Diagram of grinding the eccentric relief angle.

2.4.3. Eccentric relief angle

With the tool grinder to grind an eccentric relief angle, the
NC path is generated according to the outside diameter of
cutting tools, tilt angle and shape of wheels, and the relief
angle. The grinding sequence is: X, Y, C, and A axes start at
the same time, and shift to the approach distance of grind-
ing face of a wheel and the cutting face of a milling cutter.
According to various wheels, the rotation degrees of A-axis are
different. Z-axis moves downward to the approach distance.
Finally, X, Y, and C axes start simultaneously to grind the cut-
ting edge from the base to the end face. X-axis returns in the
horizontal direction to make the wheel exit the groove. Then,
X, Y, and C axes return to the starting point simultaneously.
Another flute can be ground according to the sequence of the
above. Fig. 6 shows the diagram of grinding the eccentric relief
angle.
3. Experimental results and analysis
In the experiments, the tested cutting tools were the square
end mill and the ball nose end mill with two flutes and 8 mm
in outside diameter. In the practical grinding, the parame-
ters of grinding processes were fixed, only the parameters
of the approach and retract sequence are changed. The size
of cutting tools shapes maybe need to compensate in grind-
ing. Therefore, the shifting sequence and the distance of each
axis should be taken into consideration to avoid collision. In
industry, each axis will return to original point of machine and
shift to the grinding point when the grinding processes are
changed. The difference of grinding efficiency of the industrial
application and the approach and retract sequence are com-

Table 1 – Efficiency analysis of approach and retract procedures

Items Cutting tools for testing

8 mm square end mill 8 mm ball nose end mill

with two flutes with two flutes

Proposed grinding Grinding process Proposed grinding Grinding process

process in industry process in industry

Machining time (a) 354 s 396 s 424 s 471 s

Practical grinding time (b) 291 s 291 s 352 s 352
Approach and retract time (c = a − b) 63 s 105 s 72 s 119 s
Saving time of approach and retract (d) 105 − 63 = 42 s 119 − 72 = 47 s
Efficiency improved of approach and 42/105 = 40% 47/119 = 39.5%
retract (d/c)
Overall efficiency improved of 42/396 = 10.6% 47/471 = 10%
machining (d/a)
622 j o u r n a l o f m a t e r i a l s p r o c e s s i n g t e c h n o l o g y 2 0 1 ( 2 0 0 8 ) 618–622
pared, which are proposed in Section 2. Table 1 reveals that the
efficiency for the approach and retract time were improved up
to 40% and 39.5%, and the improvement of the overall machin-
ing time for the square end mill and the ball nose end mill were
10.6% and 10%, respectively. Thus the proposed grinding pro-
cesses can save the approach and retract time, and the overall
machining time effectively.
4. Conclusions
This paper constructs the complete planning and the analy-
sis of grinding processes for end mills. A five-axis CNC tool
grinder was used to grind a square end mill and a ball nose
end mill via the proposed grinding processes. Based on the
practical grinding results, the following conclusions can be
obtained:
(1) There was no collision phenomenon in the approach and
retract procedures of each axis.
(2) The efficiency for the approach and retract time was
improved approximately up to 40%.
(3) The efficiency for the overall machining time was
improved approximately 10%.
(4) The commercial tool grinding software usually uses tool
shapes to construct the CAM interface, which is not flex-
ible for customers. On the contrary, this paper adopts the
grinding processes to construct the grinding path of tools,
which are very flexible for designing cutting tools.
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