An investigation is reported on identifying valid machine tool setup conditions for grinding or milling of helical grooves using profiled disc-type cutting tools. When using existing analytical models to design cutter profiles for helical groove machining, it is often found that no valid solution can be found if the machine setup is not properly selected. In the present investigation, the criteria for obtaining a valid cutter profile are established and applied to finding the range of allowable setup conditions for both smooth workpiece profiles and profiles with one or more singular points. These results are illustrated using a CAD/CAM software package for helical groove machining.
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