S. FUJI!

Research Assistant

M. F. DeVRIES
Assistant Professor. Mem. ASME

In Analysis of Drill ieometry for Optimum Drill Design I f Compiler.

Part IDrill Geometry Analysis
A comprehensive analysis of the twist drill point geometry is made in order that the high-speed digital computer can be used as an aid in the design of a drill. This subject is treated in two parts. In Part I. the drill geometry is analyzed with respect to the drill flute and flank contours by considering cross sections of the drill cut by planes perpendicular to its axis. Since several important drill angles are defined in planes inclined, to the drill axis, the analysis is extended to cover the general case where the drill is cut by any plane inclined to its axis.

S. M. WU
Professor. Mem. ASME Department o f Mechanical Engineering, The University o f Wisconsin, Madison, Wis.

Introduction
I HE ORDINARY twist drill is a common cutting tool, yet it is characterized by a complex geometry. This complexity has led to difficulties in understanding the basic drilling operation. With t h e advent of the high-speed digital computer and Its availability as a manufacturing and design aid, previous analyses [1, 2 ] 1 of the drill were found inadequate; hence, a comprehensive geometrical analysis of the twist drill is needed. The purpose of this paper is to make an analysis of the drill point geometry such that a computer can be utilized to describe and further analyze the drill geometry. T h e investigation assumes a drill with straight cutting edges. The drill flute and flank shapes are first analyzed in a plane perpendicular to the drill axis. Drill point cross sections in planes inclined to the drill axis were analyzed to describe the drill point geometry including the face rake and nominal relief angles. The drill margin is not considered in this analysis. In this investigation, an orthogonal cutting plane is defined as a plane perpendicular to the drill axis. An oblique cutting plane is then defined as a plane that cuts the drill at any angle other than perpendicular to the drill axis.

body; however, the basic geometry of the drill point can be analyzed in two dimensions by generating a series of cross sections in orthogonal or oblique cutting planes, as illustrated in Figs. 1(a) and 1(6), respectively. T h e flute and flank surfaces appear in the two-dimensional cross sections as curves which can be expressed by mathematical functions that can be evaluated by a computer. The drill flute contours in the orthogonal reference plane are developed first. T h e flute location in tin arbitral'}' orthogonal cutting plane is then related to its location in the reference plane. T h e intersections of the drill grinding cones and an orthogonal cutting plane are ellipsesa portion of which determines the drill flank contour. Once the flute and flank contours in a particular plane are known, the two can be combined to obtain drill point cross section in that plane. The analysis of the conventional twist drill point geometry is based upon the approach introduced by Galloway [1] and assumes conical grinding (described in Appendix 1). Illustrated in Fig. 2 is the right-hand coordinate system used by Galloway. The coordinate system is described as: 1 The z-axis is the drill axis with the positive direction toward the drill shank. 2 The //-axis is a perpendicular common to the extensions of the two cutting edges and the z-axis. ''> The x-axis is perpendicular to the y- and z-axes. Throughout this paper the ,r</-plane, shown in Fig. 2, is referred to as the original or orthogonal reference plane. Flute Shape. The full shape of the drill flute contours are shown in Fig. '2(d) as curves BCD and B'C'IV, which are obtained by cutting the drill body with an orthogonal cutting plane. The orientation of the contours with respect to the x- and //-axes will depend on the location of the cutting plane in the drill body. The flute contours are shown in the orientation which is also assumed for them in the orthogonal reference plane. In practice, half of the drill flute, corresponding to curve CD (or C D ' )
AUGUST 19 7 0 / 647

Geometrical Analysis of the Twist Drill Point in an Orthogonal Cutting Plane

The important features of a drill point are described by its flute and flank shapes. T h e drill point is a three-dimensional

1 Numbers in brackets designate References at end of paper. Contributed by the Production Engineering Division and presented at the Production Engineering Conference, Madison, Wise,

March 23-25, 1970, of T H E AMERICAN SOCIETY OF MECHANICAL

ENGINEERS. Manuscript received at ASME Headquarters, December 18, 1969. Paper No. 70-Prod-5.

Journal of Engineering for Industry Copyright 1970 by ASME

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Fig. 1

Orthogonal and oblique cutting planes

in Fig. 2(d), is designed by considering both the drill strength and chip ejection space. The other half of the flute, i.e., the curve BC (or B ' C ) in Fig. 2(d), is designed to produce a straight cutting edge for a specified combination of point angle 2K, helix angle y0, web thickness 21, and drill diameter 2R. The flute contour analysis that, leads to a drill having straight cutting edges was originally developed in reference [1]. The flute contour in the orthogonal reference plane (x, if) can be described in terms of the parametric equations: r t cosec <j> v = <f> -f- t tan 70 cot 4> col. K (I)

lationship between drill, grinding cone, and coordinate system

where / and v are the polar coordinates of the (lute contour in the reference plane. While r is a function of the web thickness 21 and the web angle 4>, the angle v is related to the web thickness 21, the helix angle 70, the half point angle K, and the web angle <p. By varying the web angle r/>, for given values of 70, I and K, values of the polar coordinates r and v can be calculated which trace the locus of the flute contour in the reference plane. The position of the drill flute contour in the reference plane was first established in the position as shown in Fig. 2(d) and the upper view in Fig. 3. The position of the flute contour in any orthogonal cutting plane can be determined by rotating the flute cross section in the reference plane around the drill axis by an angle f

NomenclatureR = drill radius ( = l /a drill web thickness 7 , = drill helix angle at the periphery K = V2 drill point, angle Q = grinding cone semiangle d = ^-coordinate of grinding cone vertex for left side flank surface (Fig. 2) ip = angle between the .r-axis and the line of intersection AA' of the tangent plane of the cone at its generatrix passing through the corresponding outer and chisel edge corners with the :r</-plane (Fig. 2) I <f> = drill web angle = sin ' a = nominal relief angle a'o = nominal relief angle at the outer corner 7 = face rake angle f = flute rotation angle (Fig. 3) co = angle between the x- (or u-) axis and the projection of the cone axis on the xy(orm>-) plane X = angle between the cone, axis and a cutting plane (Figs. 4 and 11) p = inverse cosine of cone axis direction cosine n' in oblique cutting plane analysis p, i] rotation angles which define the oblique coordinate system {it, v, w) to the orthogonal coordinate system (x, y, z) f = distance between the orthogonal reference plane and any orthogonal cutting plane ft = distance between the oblique reference plane and any parallel oblique cutting plane p,q,h = parameters in the transformation equations between coordinate systems (.To, J/o) and (xu yf) or (o, Wo) and {iii, i)
(Continued on next pagp)

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between the grinding cone and the drill. The grinding cone position is defined by the cone vertex position and the direction cosines of the cone axis with respect to the x-, y-, and z-axes. The cone vertex lies on the extension of the cutting edge and, as shown in Fig. 2, its coordinates (x, ;/, z) are: xv = -d i.4)

Vv = ~t z = xv cot K = d cot K

Fig. 3

Flute contour rotation

which is related to the drill helix angle 70 and the distance / Uetween the orthogonal cutting plane and the reference plane. The rotation angle f can be observed in Fig. 3 as: f = tan 7 (2)

where d is an independently deterniined variable that specifies the cone vertex position. The z-coordinate of the cone vertex is directly related to the half point angle K and x,.. The cone axis direction cosines I, m, and n are with respect to the x-, ;/-, and z-axes. The direction cosines are based on the definition of the cone vertex position given by equation (4) and are shown in Appendix 1. Once the grinding cone characteristics are determined, the drill flank surface is a portion of the grinding cone surface. Therefore, a portion of the intersection resulting from the cut ting of the grinding cone by an orthogonal cutting plane is the drill flank contour. To obtain a reasonable flank shape, the direction cosine n of the cone axis with respect to the drill axis is related to a supplementary angle X defined as:

x = T-

(">)

In any orthogonal plane cutting the drill, e.g., the lower plane .-lwn in Fig. 3, the projections of the x- and (/-axes from the reference plane are denoted as the Xo- and j/0-axes in the cutting plane. In the same arbitrary plane the x'- and (/'-axes represent the original x- and (/-axes as the}' are rotated by the angle f. [11 conjunction with the x- and j/-axes, the flute position in the reference plane is rotated by the same angle f. Also, the point \' in the reference plane can be denoted after rotation by the point A with coordinates (x0, ?/,/). The relationship between the coordinate systems (xo, 1/0) and {x', y') is given by the following orthogonal transformation: cos t sin f -sin 1 cos f (3)

The limits of X are > X > Q to yield an ellipse, a portion of which is the flank contour in an orthogonal cutting piano. Therefore, the first step in developing the drill flank contour is to generate the proper ellipse. The procedure for generating the ellipse can be best explained through the use of a figure. Consider the cross section of the grinding cone ACD in the plane which includes the cone axis AB and is perpendicular to the orthogonal cutting plane ODE as shown in the lower part of Fig. 4. The angle between the cone axis and the cutting plane is X. The z-coordinate of the cone vertex A is shown as z and is defined in terms of the original coordinate system. The distance between the orthogonal reference plane and the cutting plane is denoted by / . Thus, the cutting plane passes through the grinding cone at a distance c from the cone vertex where: / = d cot K + /

Flank Shape. The drill flank surfaces are generated by grinding cones symmetric about the drill axis as shown in Fig. 14 in Appendix 1. The two flank surfaces are theoretically the same because they are generated by symmetric grinding cones A and B. Throughout this paper only the left-side flank surface of the drill is considered. The drill flank surfaces are determined by the drill point angle 2K, the nominal relief angle at the outer corner a 0 , and the characteristics of the grinding cone. The grinding cone characteristics are given by the cone semiangle 6 and the relative position

For a given grinding cone and value of/, the ellipse that results from the intersection of the grinding cone and the cutting plane is shown in the upper part of Fig. 4. The ellipse in the upper part of Fig. 4 is determined by projecting its major axis CD from the lower part and by the location of Point F. The coordinates of Point F are determined from the upper part of

Nomenclature(x, y, z) = coordinate system defined for the orthogonal cutting plane analysisdescribed by Fig. 2 (it, v, w) = coordinate system defined for the oblique cutting plane analysisdescribed by Fig. 8 (xo, i/o) = projections, through the distance /, of the x- and yaxes on any orthogonal cutting plane (o, vo) = projections, through the distance / i , of the u- and w-axes on any oblique cutting plane (xi, ?/i) = auxiliary coordinate system in an orthogonal cutting plane used to express a conic in standardized form and related to the coordinate system (xo, y) through the angle co and translation parameters ('i, VI) = auxiliary coordinate system in an oblique cutting plane used to express a conic in standardized form and related to the coordinate system (no, %) through the angle co and translation parameters (x', (/') = auxiliary coordinate system in an orthogonal cutting plane used to describe flute contour rotation and related to the coordinate system (xo, ,Vo) through the angle f (I, m, n) = cone axis direction cosines in the orthogonal coordinate system (x, (/, z) (V, m', n') = cone axis direction cosines in the oblique coordinate system (u, v, w)
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8,

82 Fig. 4 Flank ellipse d e t e r m i n a t i o n

Fig. 4 by noting that Point F is the intersection of a cone generatrix (A"F) and a line through Point B perpendicular to the cone axis A"B and lying on the cutting plane CDE. The ellipse can be expressed in the auxiliary coordinate system (xi, i/i) in standardized form as: 1 (7)

where p = - x t cos oi + y, sin co h q = x sin co j/ cos co h = | c { c o t (X - 0) + col (X + 6)\

where a and h are the semimajor (CO' in Fig. 4) and semiminor (GO' in Fig. 4) axes, respectively, and a = - ejcot ( X - 8) - cot (X + 6)} e tan 0\ cot (X - 0) - cot (X + 0)\_ ~ 2 sin X[{cot (\~^W^coi Xj {cot, X ^ ^ T ( X ~ + 7 ) j T ^ as derived in Appendix 2. Complete Drill Point Cross Sections. The complete drill point cross section can be drawn by superimposing the drill flute contour in an orthogonal cutting plane and the ellipse resulting from the intersection of that cutting plane with the grinding cone. The mathematical procedure used to achieve this objective is to make a transformation of the ellipse given in Fig. 4 from the coordinate system (x,, i/i) to the coordinate system (x0, j/o). Previously, the :r0- and j/o-axes were defined as the projections of the x- and j/-axes of the original coordinate system on the cutting plane. The Xi-axis coincides with the projection of the cone axis on the cutting plane. The transformation can be made in two steps: first, by finding the rotation angle co, i.e., the angle between the xvaxis and the Xi-axis; and second, by establishing the relationship between the coordinates of the projected cone vertex expressed with respect to both the coordinate systems (xh j/i) and (x0, j/ 0 ). The equation for the transformation of coordinates is (see Appendix 3): x0 \ Vol / cos co sin co cos co (8)

tan |co| = | -

if - > 0, co < 0 and if ' < 0, co > 0.

Fig. 5 portrays the results of the superimposition of the flute contour and the flank ellipse on a cutting plane. The portion of the ellipse PQ that lies between drill flutes is the drill flank contour in that plane. Only one flute contour (referred to as Flute 1 in Fig. 5) is considered in the preceding analysis and the intersection of that contour and the ellipse (referred to as Ellipse 1) is at Point P. The complete shape of a drill point cross section in an orthogonal cutting plane is generated by noting that Flute 2 and Flank 2 of Fig. 6 are symmetric to Flute 1 and Flank 1 of Fig. 5 with respect to the origin of the coordinate system (x0, yQ). The por-

\ si" oi
1970

Fig. 5

Superposition of drill flute contour a n d flank ellipse

650

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cutting plane (Fig. 1(b)) will yield additional useful information about the drill geometry. The oblique cutting plane can be related to the original orthogonal cutting plane and coordinate system. The flute and the flank contours in oblique cutting planes can then be analyzed. New Coordinate System for the Oblique Cutting Plane. In Fig. 8 plane 1\ is inclined to the drill axis on which the cross section of the drill will be obtained. A plane, P0, which is parallel to the cutting plane Pi and passes through the origin of the original orthogonal coordinate system (x, y, z), is used as a new oblique reference plane: and, a new coordinate system (w, v, w) is established with respect to plane l\ as follows: 1 The (/-axis corresponds to the intersecting line AB of the original reference plane (i.e., :ri/-plane) and the new reference plane P0.

Fig. 6

Drill point cross section in orthogonal plane

Fig. 7

Influence of the f dimension on the flank ellipse and flute contour

tions PQ and RS of the two ellipses located between Flutes 1 and 2 are the flanks of the drill point, while the cross section of a drill point in the orthogonal cutting plane is the shaded area PQRS bounded by the four curves in Fig. 6. The change in the drill cross section in different cutting planes can be investigated by repeating the procedure outlined above in other orthogonal cutting planes, i.e., by varying the distance / between the reference plane and the cutting plane. As an example, the relationship between two cross sections is shown in Fig. 7. The ellipse described in Figs. 4 and 5 is shown in Fig. 7 as Ellipse 1 with dimensions and coordinates given by the superscript 1. The flank ellipse in a second plane, designated as cutting plane 2, is referred to as Ellipse 2 with dimensions and coordinates given by the superscript 2. Note that the distance between the reference plane and cutting plane 2 is less than the distance between the reference plane and cutting plane 1. Thus, Ellipse 2 will be smaller than Ellipse 1 and will be shifted along the zi-axis in the negative direction as shown in Fig. 7. The flutes in each cutting plane are located in their properly rotated positions corresponding to the distance / and the drill helix angle. Therefore, the flank contours obtained for the two cutting planes are P'Q 1 and P 2 Q 2 , respectively.

Geometrical Analysis of the Twist Drill Point in an Oblique Cutting Plane

An analysis utilizing a drill point cross section in an oblique

Fig. 8 Relationship between the orthogonal (x, y, z) and oblique (u, , w ) reference systems

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2 The u-axis is perpendicular to the v-axis passing through the origin and lies on the new reference plane Pa. 3 The (('-axis is perpendicular to the u- and (.'-axes and passes through the origin of the original coordinate system. The new coordinate system (u, v, w) is obtained by: 1 liotatiou of the x- and ;i/-axes clockwise by an angle p around the z-axis as shown in Fig. 8(a) yielding the x'- and j/'-axes. 2 Rotation of the x'~ and z-axes counterclockwise by an angle TJ around the (/'-axis as shown in Fig. 8(6) yielding the u- and waxes. 3 The (/'-axis is designated as the (.'-axis in the new coordinate system. Angles p and >; are positive when the rotations follow the directions defined above. The relationship between the coordinate systems (x, y, z) and (u, v, w) is given by the transformation matrix M, as well as the position of the cone vertex (x y,,, zv) and (., v, wv), and the direction cosines of the cone axis (I, m, n) and (V, m', n') (Appendix 4):

Oblique Cutting Plane P,

Orthogonal Culling Plane Pj

Fig, 9

Flute contour analysis in an oblique cutting plane

(1) (2) (3)

ellipse parabola hyperbola

- > X > X = 8 6 > X> 0

(H) (116) (lie)

= M

where \ =and = Ml
m

- 11

if n' > 0 if n' < 0

(9) X = ,*-

where /cos p cos >; \l = I sin p \eos p sin r; sm p cos T) cos p sin p sin ij sm i) 0
COS t]

and (a) Ellipse. If the angle X is between TT/2 and 0 as shown in equation ( H a ) , the flank shape can be determined in the oblique cutting plane from the flank ellipse analysis in an orthogonal cutting plane after modification from the orthogonal to the oblique coordinate system. When n' = 1, a circle will appear as a special case of the ellipse. If the projection E of the cone vertex lies on the positive side of the id-axis (the :ri-axis in Fig. 4), the following modification is necessary in the transformation equation given by equation (8): h = where 9
7

In addition, fh which is analogous to / , is used to describe the distance between the reference and cutting planes in the oblique case. Flute Shape. The flute shape in an oblique cutting plane can be determined from the intersecting points of the oblique cutting plane and the flutes located in orthogonal cutting planes by varying the distance / . Consider the oblique cutting plane Pi and the orthogonal cutting plane P 2 in Fig. 9 where the flute contours in plane P 2 are shown as AB and CD. The line of intersection of planes Px and Pi cuts the orthogonal plane flute eontours AB and CD at Points G and H. These points G and II are therefore points in common with the flute contours in both the orthogonal and oblique cutting planes. As the distance between the orthogonal reference plane and cutting plane Pi varies, the flute contours AB and CD in P 2 changes. If the oblique cutting plane Pi is fixed, the line of intersection between P, and the varying plane P 2 will trace out the flute contours in the oblique cutting plane. The cutting plane P, expressed in the original coordinate system (x, y, z) is: x cos p sin i) y sin p sin T) -\- z cos i) ~ fi = 0 (10)

g\ cot (X - d) + cot (X + 8)}

/.

(b) Parabola. If the angle X equals 6, the flank shape in the cutting plane is part of a parabola. The equation for the parabola is given iu the auxiliary coordinate system ( 1; v\) of Fig. 10 as:

Associated with the orthogonal cutting plane P 2 is the distance / which, when substituted for z in equation (10), gives the line of intersection between the two planes. Flank Shape. Equation (9) defines the relationship between the grinding cone and the new coordinate system (, v, w). By denoting the projections of the u- and (.'-axes on the cutting plane by the v.- and w0-axes, the flank shape can be determined with respect to (he coordinate system (uo, o) by specifying the dist a n c e / , . The direction cosine n' of the cone axis with respect to the (-axis determines the cross section of the flank surface in the oblique cutting plane as one of three types of conies; namely, an ellipse, a parabola, or a hyperbola as follows:
652 ' AUGUST 1970

~-\

A
:E

_,,.,-Grinding Cone

^ 8
Reference Plena

^ \ C(o)
- | n |

6 ^ T -- ^

iCutting Plane

ifn'<o'~f-

if n'>0

Fig. 10

Flank analysis For an oblique culling plane:

parabolic confour

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Fig. 11

Flank analysis for an oblique culling plane:

hyperbolie contour

Mi =

aih

(12)

In the case where the flank shape is a part of a hyperbola the relationships between the two coordinates (id, V\) and (o, i'o) are the same as equation (13) with the following modification: - f / { c o t (0

cot 6

X) - cot (0 + X)}

9 = |w -

/i|

The relationship between the coordinates (uh vt) and (u0, Vo) is io \ Vo ) where p = M cos co + vv siu co h q = sin cu W j . cos co h. = j cot 25
I TO i
TO,

cos co \ sin co

sin co\ / ui p cos co/ \ vx q

(13)

tan jcoj = |

if > 0, co < 0 and

if < 0, co > 0 id Hyperbola. If the angle X is smaller than 0 but greater than zero, the flank shape in the cutting plane is part of a hyperbola. The equation for the hyperbola is given in the auxiliary coordinate system (ut, \) of Fig. 11 as:
i_-

b"where = -ffjcot (0 - X) + cot (0 + X)j

(14)

g tan 0{cot (0 - A) + cot (0 + X)} ~ 2 sin X[{cot (0 - X) + cot X){cot X - eotTe + xTjT1^
0 = i>.

sign, and if where if l'n'(w ~- j\) > 0, h takes the l'n'(wr ~ .A) < 0, h takes the sign. The notation for all three of the flank surface conies involves the parameters a, b, g, and h. Note that these parameters are defined differently for each conic. Specific Oblique Cuffing Planes for Angles of Importance. The analysis of the drill point geometry in an oblique cutting plane can be of use in describing several of the angles related to drill performance. These angles include the nominal relief angle and the face rake angle, both of which can be described in terms of basic drill parameters in oblique planes. (a) Nominal Relief Angle. The nominal relief angle a is defined in reference [1]. In essence, the nominal relief angle is the angle between the orthogonal reference plane and a tangent to (he flank contour at, a point along the drill cutting edge. The nominal relief angle is measured in an oblique cutting plane which is parallel to the drill axis and is perpendicular to a radius from the drill axis to a point on the cutting edge. Once the drill flank contour in the oblique cutting plane is known for a specified point on the drill cutting edge, the nominal relief angle can be obtained. To be specific, the nominal relief angle can be obtained by the computer program in four steps: First, specify a point on the drill cutting edge; second, determine the proper transformation matrix M in terms of p and -q; third, obtain the drill flank contour iu the oblique cutting plane; and fourth, construct, the tangent, to the relief contour at, the specified point,. The determination of the nominal relief angle as if varies along the drill cutting edge can be best illustrated by an example as shown in Fig. 12. Suppose the relief angle at Point Ai on the drill cutting edge is to be determined. As shown in Fig. 12 the coordinates (xi, ;(/i, 2i) of Point Ai iu the orthogonal coordinate system are:
Xi =

/'[ COS

/.!

yi

/'i s i n c /

(15)

If the rotation of the angle r\ in Fig. 8 is counterclockwise, the flank shape is represented by negative u values if )j < w and by positive u values if r\ > w. In Fig. 11 the flank shape for the case vvliere -q is less than TT is shown. The flank shape for the V > TT case is a mirror image about the vr axis. If X = 0 (that, is, the cutting plane is parallel to the cone axis implying ' = 0), . and 6 in equation (14) reduce to: a = g cot 0 b = g

Zl =

Subsequently, the transformation matrix .1/ can be determined in terms of the parameters p and -q as given by equation (9). Hecall that the transformation matrix M enables the flank contours to be described in the coordinate system (u, v, w). From the definition of the nominal relief angle, the oblique cutting plane in which a is defined has the parameters p = 4>i a l l c ' V = w/'^Thus, the coordinates of Point Ai in the coordinate system (u, v, w) can be shown as:
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Fig. 12

Determination of nominal relief angle

--Tangent lo the Flute a! the Point A, (c) Cross Section on the Plane PLI

Ml

2l

Fig. 13

Determination of face rake angle

Hi = 0
M'I = n

(16)

13(6), and thus it is not necessary to determine a new coordinate system for each oblique cutting plane along the cutting edge. In the determination of the face rake angle the flute contour With these coordinates known, the nominal relief angle at Point in an oblique cutting plane was utilized; however, the flank At can be determined. Note also t h a t the cutting plane P [,- for Point A2 is not parallel shape was unnecessary since the face rake angle is defined with respect to the flute contour. On the other hand, in the deterto the cutting plane Pu (Fig. 12(a)). Consequently, a new comination of the nominal relief angle, it was necessary to generate ordinate system for Point A2 i.s determined in terms of the the flank shape in an oblique cutting plane while the flute conparameter c/>2. This implies that at every point on the cutting: tour is not used. edge a new coordinate system must be defined in order to obtain the nominal relief angle. References (b) Face Rake Angle. The face rake angle ya is also denned in reference [1]. The face rake angle is described in an oblique 1 Galloway, D. F., "Some Experiments on the Influence of Various Factors on Drill Performance," TRANS. ASME, Vol. 79, 1957, cutting plane which is perpendicular to the line joining the pp. 191-231. corresponding outer and chisel edge corners. The method for 2 Oxford, C. J., Jr. "On the Drilling of MetalsI, Basic Mechanobtaining the face rake angle is analogous to that for the nominal ics of the Process," TRANS. ASME, Vol. 77, 1955, pp. 103-114. relief angle except that it is the flute contour rather than the flank contour that is described in the oblique cutting plane. Suppose the face rake angle at Point Ai on the cutting edge in Fig. APPENDIX 1 13(a) is to be determined. The coordinates of Point Ai can Principle of Conical Grinding. The concept of conical grinding be expressed in the coordinate system (x, y, z) as: was given by Galloway [1] and is illustrated in Fig. 14. The flank of a twist drill is ground by the grinding wheel G as the :i'i = / tan K drill is rotated around the axis X X . Suppose the drill is con!h = -I (17) sidered stationary while the grinding wheel is rotated around the axis X X . The plane of the grinding wheel face generates a *i = / cone with the flank surface of the drill being a portion of the cone surface. This cone is referred to as the grinding cone The plane in which face rake angle is defined is given by (thus the name conical grinding). The plane of the grinding p = 0 and r) K in equation (9), hence the transformation matrix wheel face and the axis X X intersect at Point O. The vertex AI can be determined. Thus, the fiute contour can be described of the grinding cone is at the point O, while the cone semiangle in the coordinate system (u, v, w) as previously shown. The 6 is the angle between the axis X X and the generatrix lying on coordinates of Point Ai with respect to the coordinate system the grinding wheel surface. There are two symmetric grinding (u, v, w) are: cones, labeled as A and B in Fig. 14, with each cone generating one of the drill flank surfaces. The grinding motion of most , = 0 drill-grinding machines is usually more complex than that Vi = ~t (18) mentioned above, as there is some sliding motion between the grinding wheel face and the drill point. However, in those cases, wi = / sec K the grinding motion is reducible to the purely conical grinding motion at any instant of time. and the tangent to the flute contour as Point Ai gives the face rake angle at that point. Note that the cutting plane Pa for Point A2 is parallel to the cutting plane Pu, as shown in Fig. 654 / A U G U S T 1970 The grinding cone location with respect to the drill axis is specified once the four parameters K, \fr, 6, and d are fixed. Gallo-

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Grinding

Whael

Considering the intersecting Point C of the ellipse and a plane AGD which includes the projection CD of the cone axis on the cutting plane and is perpendicular to the cutting plane, the relationships for the semimajor axis a and semiminor axis b are obtained from Fig. 4. T h e coordinates (xc, yc) of Point C can be obtained from the geometry of plane ACD as follows: CD (21) J/ = 0 where CD = CE - D E = e{ cot (X - 6) - cot (X + 6>)}
AXIS of

Grinding Cone 'A'-<

Grinding

Cone

--Axis

of

and X and e are given by equations (5) and (6). Considering another intersecting point (Point F ) of the ellipse and a plane A"BF in the upper part of Fig. 4 which includes the cone axis AB and is perpendicular to plane ACD, the coordinates (xF, yF) of Point. F can be obtained from the geometry of planes A"BF and ACD. In the plane ACD, OE = /i = 01) + D E
= - c f c o t (X 6) + cot (X + 0)} (22)

Grinding Cone ' A '

Fig. 14

Conical grinding principle [ l ]

way has shown that the direction cosines /, m, and n of the cone axis with respect to x-t y~, and 2-axes are given by:

OB = OE - BE

sin \p cos K sin 6 r - I - r + Sill K COS ( (sin 2 \f/ -f~ cos2 ycos'K) 'cos \p cos K sin 5 (sin \p + cos2 i^ cos2 K)1^2

= h e cot X In the plane A"BF, (19) B F = A"B tan d = e cosee X tan 9 Tints, considering the signs of coordinates (xF, yF) with respect to the coordinate system (xi, ?/i),
X]f

sin I/" sin K sin 0

. 2

(sin xf/ + cos2 i/' cos2 K)

f/7! +

COS K COS i

Equation (19) gives the direction of the grinding cone axis in terms of the variables xp, K, and 6; the coordinates of the vertex nf ihe grinding cone (for a given web thickness) can be expressed in terms of d and K, equation (4). Hence, the grinding cone-drill axis relationship can be completely specified. The drill point shape parameters \p and K are known to be related to drill performance. Since \p is not easily measured, the nominal relief angle at the outer corner a0 is a more convenient parameter to use in drill performance studies. The relationship between the angles o and \p is given by:

= -OB
(23)

yF = B F Since Points C and F are points on the ellipse, the expressions for a and 6 in equation (7) can be obtained by substituting the coordinates given by equations (21) and (23) in equation (7) and solving the simultaneous equations.

cot \p =

1 p~\ 'A 1 IP]

tan K

t R

APPENDIX 3
(20) The Derivation of the Transformation Equations Defined by Equation

Thus, under the assumption of conical grinding and assuming a given web thickness and flute contour, the flank contour is specified by the four parameters K, a0, 0, and d. Values of the parameters K and o are usually selected on the basis of drill performance; the grinding cone parameters 6 and '' can still be independently varied. The variation in drill flank curvature is related to 0 and d.

(9). Referring to Fig. 15, the angle w between the xr and the Xi-axes was derived as [1]:
t a n i>i = -

APPENDIX 2
The Derivation of the Ellipse Equation. If an auxiliary coordinate system (xi, yt) in the cutting plane, i.e., the x0.Vo-plane, is defined Mich that the xi-axis is the projection BE of the cone axis AB on the cutting plane, and the -i/i-axis is perpendicular to the iaxis and passes through the center O' of the ellipse as shown in Fig. 4, the ellipse which is generated can be defined in standardued form by equation (7):
?/i 2

where I and in are the direction cosines of cone axis given by equation (19) in Appendix 1. The relationship between the original and the auxiliary coordinate systems (x0, y0) and (xi, yi), respectively, is such that the XT and !/i-axes are rotated by the angle u> clockwise in the left-hand system around its origin and translated to the origin of the coordinate system (x0, J/ 0 ) as shown in Fig. 15 (refer also to Fig. 5). If new x'- and j/'-axes are obtained Vjy rotating the x\- and j/i-axes by the angle co around the origin of the coordinate system (xi, ?/i), a point with the coordinates (xi, j/i) is expressed in the new coordinate system (x1, y') by:

a"1

62

= 1

A_
AUGUST

(24)

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!/-, and vj-axea with respect to the original x-, i/-, and 2-axes be Xi, Hi, ci; Xj, p 2 , i'2; X3, ^3, v3, respectively. From Fig. 8 equation (9) can be given bj':
Xi Mi p-1

v\

x2
X,
-KM

Ms

/*

r
\*

where X! = cos p cos >; Hi = cos

Projector) of the Cone Verle*

p I cos ?; = sm p cos r/

Pi

COS

-sin

JJ

Fig. 15 (xo, yo)

T r a n s f o r m a t i o n of c o o r d i n a t e system ( x j , y d to c o o r d i n a t e system

X2

cos | - - p cos p

sm p

where
S i l l CO

T =
COS CO

v, = cos - = 0 2 cos p cos - V cos p sm rj

Since the coordinate systems (.To, yo) and (x', y') are parallel, the following relationship exists between them: (25) where r and s are shown in Fig. 15. The coordinates of the projected cone vertex E in the x0(/0-plane are expressed by (x,., //) and ( /(, 0) with respect to the coordinate systems (xo, i/o) and (xi, yi), respectively. Therefore, the following relationship between these two coordinates of the point E is obtained by applying equations (24) and (25): 7 -h 0 Solving equation (26) with respect to r and s yields: T
T/J.3

COS

- V

-sm p sm i]

Vz

COS 1)

A plane perpendicular to the -uj-axis and passing through a point with the coordinates (xp, yp, zp) is expressed by: /oX3(x - x) + kfx3(y - yp) + kv3(z zp) 0 (28)

(26)

where k is an arbitrary number which is not zero. equation (28) by k yields:

Dividing

X3(x - x p ) + fi:s(y ~~ y) + v3(z - zp) = 0

(271

(29)

Vv

Since the (,'-plane i'o (Fig. 8) passes through the origin 0 with the coordinates (0, 0, 0), the plane P 0 is expressed by: X3x + mi + vsz 0

Thus, substituting equations (24) and (27) into equation (25) and simplifying, the expressions in equation (8) are obtained. The expression for h in equation (8) is equation (22) in Appendix 2. Note that if the point E lies on the positive side of the Xi-axis, the expression for h in equation (8) must be modified as follows: 1 cjcot (X - d) + cot (X + S)\

Since the plane Pi passes through the point 0 ' (Fig. 8) with the coordinates (0, 0,/i) expressed with respect to the coordinate system (u, v, iv), the coordinates of the point O' are expressed in the coordinate system (x, y,z) using equation (9) as:
x

/i

cos

P sin 7} (30)

V = /i sin p sin r\

APPENDIX 4
The Relationship Between the Orthogonal and the Oblique Coordinate System. Referring to Fig. 8, let the direction cosines of the u-,

zP = /i

cos

Substitution of equation (30) in equation (29) yields equation (10).

656 / A U G U S T 19 7 0

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