Decomposition of forging die for high speed machining (original) (raw)
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Decomposition of forging dies for machining planning
Computing Research Repository, 2009
This paper will provide a method to decompose forging dies for machining planning in the case of high speed machining finishing operations. This method lies on a machining feature approach model presented in the following paper. The two main decomposition phases, called Basic Machining Features Extraction and Process Planning Generation, are presented. These two decomposition phases integrates machining resources models
A knowledge base model for complex forging die machining
Computers & Industrial Engineering, 2011
Recent evolutions on forging process induce more complex shape on forging die. These evolutions, combined with High Speed Machining (HSM) process of forging die lead to important increase in time for machining preparation. In this context, an original approach for generating machining process based on machining knowledge is proposed in this paper. The core of this approach is to decompose a CAD model of complex forging die in geometric features. Technological data and topological relations are aggregated to a geometric feature in order to create machining features. Technological data, such as material, surface roughness and form tolerance are defined during forging process and dies design. These data are used to choose cutting tools and machining strategies. Topological relations define relative positions between the surfaces of the die CAD model. After machining features identification cutting tools and machining strategies currently used in HSM of forging die, are associated to them in order to generate machining sequences. A machining process model is proposed to formalize the links between information imbedded in the machining features and the parameters of cutting tools and machining strategies. At last machining sequences are grouped and ordered to generate the complete die machining process. In this paper the identification of geometrical features is detailed. Geometrical features identification is based on machining knowledge formalization which is translated in the generation of maps from STL models. A map based on the contact area between cutting tools and die shape gives basic geometrical features which are connected or not according to the continuity maps. The proposed approach is illustrated by an application on an industrial study case which was accomplished as part of collaboration.
Analyzing possibilities of improving machinning process planning and optimization
Main activities of the technological preparation of production refer to the process planning and optimization. Process plans as the most significant objects of optimization in production systems are characterized by variant solutions in all stages, from the selection of raw material and manufacturing technologies, types and sequences of processes and machining operations, types and characteristics of manufacturing resources, machining parameters and strategies, with machining time, cost, accuracy and surface quality as main objective functions of process planning optimization. Main goal of this paper is to analyze the possibilities of improving technological preparation of production, or precisely, to improve process planning and optimization of manufacturing process plans through the application of feature technologies and the considered simulation technique. The application of feature technologies will be analyzed from the aspect of possible integration of product design and process planning, while the application of the simulation technique within the CAD/CAM system will test the influence of variants of machining operations and machining strategies on the process planning optimization from the aspect of machining time. process planning, optimization, feature technologies, simulation technique Two basic activities within the product development are product design and product manufacturing which ought to be integrated and connected at the greatest possible extent. Technological preparation of production represents the main integr that should meet design requirements of product designers on one hand, and to adopt manufacturing possibilities of production on the other hand [1]. Main activity of the technological preparation refers to the manufacturing process planning and optimization. The imperative of modern global production is to generate rational and optimal process plans, in accordance with the basic optimization criteria such as productivity, cost-effectiveness, machining accuracy and surface quality [2]. Process planning represents the complex multi-dimensional problem that depends on the input data and set requirements according to the observed product/s, as well as the techno-economic conditions and subjective preferences of the product designer. The most important input data for process planning are product drawings which possess information about materials, dimensions, machining accuracy, surface quality, production volume and available manufacturing resources, such as raw materials, machines, tools, fixtures, measuring instruments etc. Accordingly, various process plans can be predicted for the same manufacturing conditions and which can be evaluated using various optimization criteria [3]. ng conditions, modern CAD programming systems based on feature technologies, or the application of features in modeling, are mainly used for product design and for defining technological documentation. However, the attention of product designers is focused on realizing functional characteristics of products and parts, whereby they use features in modeling which generally do not match the typical manufacturing features. By that, the process planning, as well as the integration of CAD, CAPP and CAM systems is more difficult to achieve [4]. According to above mentioned, the first task of this paper is related to the analysis of possibilities of modeling products by applying features that match with manufacturing features which are used in machining processes. In this way, it is intended to facilitate the manufacturing process planning, as well as the integration of activities of product design and process planning through direct application of features from CAD systems to machining process within CAM systems.
Machining process planning using Decomposition of Delta Volume
2007 IEEE International Symposium on Assembly and Manufacturing, 2007
A methodology for decomposition of material removed volumes so called Delta Volumes according to the natural sequences of machining is proposed. Tool classification and coding system for automatic characteristics and parameter extraction is presented. Algorithms for identification of major access directions and machining complexity and rules determining operations and tools for roughing and finishing are presented. This article suggests a technique that generates machining operation sequences with appropriate combinations of tool and machine directly from the 3D model of a part and a given block..
Journal of Zhejiang University SCIENCE A, 2013
For the designing of cutting-dies is a complex and experience-based process, it is poorly supported by conventional 3D CAD software. Thus, the majority of design activities, including the (re)modeling of those cutting die-components that are directly responsible for performing shaping operations on a sheet-metal stamping part, traditionally still need to be carried-out repetitively, separately, and manually by the designer. To eliminate some of these drawbacks and upgrade the capabilities of conventional 3D CAD software, this paper proposes a new methodology for the development of a parametric system capable of automatically performing a (re)modeling process of compound washer dies' cutting-components. The presented methodology integrates CATIA V5 built-in modules, including Part Design, Assembly Design and Knowledge Advisor, publication mechanism, and compound cutting die-design knowledge. The system developed by this methodology represents an 'intelligent' assembly template composed of two modules GAJA1 and GAJA2, respectively. GAJA1 is responsible for the direct input of the die-design problem regarding the shape, dimensions and material of the stamping part, its extraction in the form of geometric features, and the transferring of relevant design parameters and features to the module GAJA2. GAJA2 interprets the current values for the input parameters and automatically performs the modeling process of cutting die-components, using die-design knowledge and the company's internal design and manufacturing standards. Experimental results show that this system significantly shortens the modeling-time for cutting the die-components, improves the modeling-quality, and enables the training of inexperienced designers.
Machining Strategy Choice: Performance Viewer
Advances in Integrated Design and Manufacturing in Mechanical Engineering II, 2007
Nowadays high speed machining (HSM) machine tool combines productivity and part quality. So mould and die maker invested in HSM. Die and mould features are more and more complex shaped. Thus, it is difficult to choose the best machining strategy according to part shape. Geometrical analysis of machining features is not sufficient to make an optimal choice. Some research show that security, technical, functional and economical constrains must be taken into account to elaborate a machining strategy. During complex shape machining, production system limits induce feed rate decreases, thus loss of productivity, in some part areas. In this paper we propose to analyse these areas by estimating tool path quality. First we perform experiments on HSM machine tool to determine trajectory impact on machine tool behaviour. Then, we extract critical criteria and establish models of performance loss. Our work is focused on machine tool kinematical performance and numerical controller unit calculation capacity. We implement these models on Esprit ® CAM Software. During machining trajectory creation, critical part areas can be visualised and analysed. Parameters, such as, segment or arc lengths, nature of discontinuities encountered are used to analyse critical part areas. According to this visualisation, process development engineer should validate or modify the trajectory.
OPTIMIZATION OF CUTTING STRATEGIES FOR FORGING DIE MANUFACTURING ON CNC MILLING MACHINE
In present scenario it is necessary to optimize the cutting strategies for forging die manufacturing on CNC milling machines. Manufacturing of dies has been presenting greater requirements of geometrical accuracy, dimensional precision and surface quality as well as decrease in costs and manufacturing times. In this study, effects of the cutting parameters on geometrical error have been examined on a representative die cavity profile. Design of Experiment Method has been employed to find out the effects of the cutting parameters on the geometrical accuracy of the manufactured cavity profile. Prediction formula is derived to estimate the geometrical error value in terms of the values of the cutting parameters. Validity of the prediction formula has been tested by conducting verification experiments for the representative die geometry and die cavity geometry of a forging part used in industry.
1 Machining Strategy Choice : Performance Viewer
2018
Nowadays high speed machining (HSM) machine tool combines productivity and part quality. So mould and die maker invested in HSM. Die and mould features are more and more complex shaped. Thus, it is difficult to choose the best machining strategy according to part shape. Geometrical analysis of machining features is not sufficient to make an optimal choice. Some research show that security, technical, functional and economical constrains must be taken into account to elaborate a machining strategy. During complex shape machining, production system limits induce feed rate decreases, thus loss of productivity, in some part areas. In this paper we propose to analyse these areas by estimating tool path quality. First we perform experiments on HSM machine tool to determine trajectory impact on machine tool behaviour. Then, we extract critical criteria and establish models of performance loss. Our work is focused on machine tool kinematical performance and numerical controller unit calcula...
Archives of Materials Science, 2007
High speed machining became a common machining solution for various machining applications. This fact is caused by many advantages that HSM can offer to manufacturers-good surface quality, shorter production cycles etc… Yet, the main problem producers faces here is increasing costs generated by high cutting tool price used in this application. This problem is common denominator most of the today high speed machining investigation. The paper shows an example of solving the problem by analyzing chip shape generated in this process in order to determine minimal cutting speed to be used in high speed area. In that sense it has been introduced new factor authors called "measure of segmentation", Ms, used to make clear distinction between conventional and high speed regions. Therefore, this cutting speed or cutting regime can contribute in increasing cutting tool life and improving economic benefits of HSM processes.