Parameter decoupling modeling and manufacturable domain solving method for end mill flute based on five-axis grinding machine

Aiming at strong multi-parameter coupling and difficult manufacturability evaluation in five-axis grinding of end mill flutes, a parameter decoupling and manufacturable domain solving method is proposed. A wheel-pose transformation model with static adjustment and dynamic linkage stages is established, deriving mapping relationships between the machine-axis motion variables X, Y, Z, B and C and the flute geometric parameters, including the core radius R0, flute opening angle W0 and radial rake angle γ0. The parameter relationships are clarified, showing that the helix angle is directly governed by the machine-axis setting, the radial rake angle depends on the contact-point position and helix angle and the core radius and flute opening angle are strongly interdependent. A multi-constraint mathematical model of the manufacturable domain is constructed, and a grid discretization and inverse optimization-based algorithm are developed to efficiently identify feasible regions in the three-dimensional parameter space. Case calculations show a maximum relative numerical error of 0.28%, while the measured geometric deviations in the grinding experiment remain within the prescribed engineering tolerances. The experimental results agree well with the theoretical predictions, supporting the validity of the geometric model and the applicability of the proposed manufacturability-analysis framework under the investigated grinding conditions. This work provides theoretical support and methodological tools for integrated digital design and manufacturing of complex-flute end mills.