scholarly journals Determining the Optimum Parting Direction in Plastic Injection Molds Based on Minimizing Rough Machining Time during Mold Manufacturing

2016 ◽  
Vol 37 (1) ◽  
pp. 194-201 ◽  
Author(s):  
L. A. Sarmiento-Merida ◽  
A. Guevara-Morales ◽  
U. Figueroa-López
Keyword(s):  
Rough Machining ◽  
Machining Time ◽  
Parting Direction ◽  
Plastic Injection

Optimal Rough Machining of Sculptured Parts on a CNC Milling Machine

1993 ◽  
Vol 115 (4) ◽  
pp. 424-431 ◽  
Author(s):  
Z. Dong ◽  
H. Li ◽  
G. W. Vickers
Keyword(s):  
Production Costs ◽  
Depth Of Cut ◽  
Cnc Milling ◽  
Rough Machining ◽  
Machining Time ◽  
Tool Paths ◽  
Cnc Milling Machine ◽  
Cnc Programming ◽  
Sculptured Parts ◽  
Optimal Approach

An optimal approach to the rough machining of sculptured parts with least machining time is presented. The contour map cutting method is used to generate CNC tool paths based on the CAD model of sculptured parts. The part and stock geometry related parameters, including the number of cutting layers and the distributions of cutting depth, and the process parameters of feed rate and depth of cut, are optimized. The method can automate CNC programming for sculptured part rough machining, considerably improve productivity, and lower production costs. Two examples are used to illustrate the approach and its advantages.

A novel tool-path generation method for five-axis flank machining of centrifugal impeller with arbitrary surface blades

2016 ◽  
Vol 231 (1) ◽  
pp. 155-166 ◽  
Author(s):  
Hong-Zhou Fan ◽  
Shang-Jin Wang ◽  
Guang Xi ◽  
Yan-Long Cao
Keyword(s):  
Tool Path ◽  
Tool Path Generation ◽  
Ruled Surface ◽  
Centrifugal Impeller ◽  
Flank Milling ◽  
Path Generation ◽  
Rough Machining ◽  
Machining Time ◽  
Geometrical Structures ◽  
Five Axis

The centrifugal impeller with arbitrary surface blades is a very important component in automobile, ships, and aircraft industry, and it is one of the most difficult parts to process. Focusing on the machining efficiency improvement, combining the geometric advantages of ruled surface and arbitrary surface, and utilizing the efficient and accurate advantages of flank machining and point machining, this article presents a novel and targeted tool-path generation method and algorithm for five-axis flank machining of centrifugal impeller with arbitrary surface blades. In light of specific characters of different surfaces, the analyses of two different impeller blades are proposed first, the more characteristic and complex geometrical structures of the arbitrary blade are achieved. In rough machining, an approximate ruled surface blade is obtained, and a simple channel is achieved; the flank milling of the centrifugal impeller with ruled surface blades is achieved relative to the point milling of the centrifugal impeller with arbitrary surface blades; and the triangle tool path planning method is added in this process to save the machining time and cost collectively. Furthermore, in semi-finish machining, the approximate sub-ruled blade surfaces are calculated, and a new flank milling method of the sub-ruled blade surfaces is achieved; a new solution for tool interference is achieved in this process and the generation of non-interference tool paths becomes easy. Machining experiments of two different impellers are presented as a test of the proposed methods.

Time Molding in Rough Milling of Circular Cavity

2012 ◽  
Vol 723 ◽  
pp. 87-93
Author(s):  
Xiao Ping Ren ◽  
Zhan Qiang Liu ◽  
Yi Wan
Keyword(s):  
High Speed ◽  
Manufacturing Industry ◽  
Cutting Speed ◽  
Circular Cavity ◽  
Rough Machining ◽  
Machining Time ◽  
Workpiece Surface ◽  
High Productivity ◽  
Radial Depth ◽  
Rough Milling

Numerical controlled milling is widely used in the manufacturing industry because of its high productivity and workpiece surface quality. The aim of this work is to establish a methodology to evaluate the rough machining time and to predict optimal values of cutting speed to minimise machining time of circular cavity, during high speed milling. The circular cavity is divided into volumes distributed according to the real radial depth. The obtained results show that the proposed method is consistent with the actual situation.

scholarly journals Prompt Estimation of Die and Mold Machining Time by AI Without NC Program

2021 ◽  
Vol 15 (3) ◽  
pp. 350-358
Author(s):  
Hiroki Takizawa ◽  
Hideki Aoyama ◽  
Song Cheol Won ◽  
◽  
◽  
...  
Keyword(s):  
Computer Aided Design ◽  
Surface Curvature ◽  
Numerical Control ◽  
Color Information ◽  
Rough Machining ◽  
Machining Time ◽  
Machined Surface ◽  
Nc Program ◽  
Computer Aided ◽  
Shape Data

Machining time estimation is essential for the due-date estimation of products as well as for production planning. Conventionally, machining time has been estimated by a computer aided manufacturing (CAM) system, which requires time and effort to create its numerical control (NC) program and requires machining expertise to operate it. In addition, among the problems with conventional methods, an error in the estimated machining time arises owing to the machine tool’s control characteristics. In this study, an artificial intelligence (AI)-based system capable of estimating machining time promptly and simply based on shape data without requiring any NC program is developed. The input data to the AI system are color information regarding the machined depths, which are used to estimate the rough-machining time, and color information regarding the machined surface curvature distributions to estimate the finish-machining time. Color information on the machined depths and machined surface curvature distributions is created using three-dimensional computer aided design (3D CAD) data. To build the AI system, the shape data and machining time data accumulated at the machining site are used, so that the machining time estimated reflects the machining method, machining expertise, and the machine tool characteristics employed.

Parting Direction and Parting Planes for the CAD/CAM of Plastic Injection Molds

1997 ◽  
Author(s):  
Kiyoshi Urabe ◽  
Paul K. Wright
Keyword(s):  
Computer Aided Design ◽  
Concurrent Design ◽  
Design Environment ◽  
Part Geometry ◽  
Molded Part ◽  
Mold Making ◽  
Cad Cam ◽  
Parting Direction ◽  
Aided Design ◽  
Plastic Injection

Abstract We describe a plastic injection mold making agent that is part of a domain unified computer-aided design environment. This environment enables concurrent design of the “to-be-molded” part, by facilitating communication between electrical and mechanical engineering CAD tools. Once the design is completed and certain constraints are satisfied, the design is passed to the mold making agent. After the designer inputs some mold parameters, the mold agent automatically determines the parting direction and parting plane, and generates the mold halves. This is achieved by applying a set of heuristic rules on the part geometry. These rules, design constraints, and methods used to generate the mold are discussed. Resulting mold halves have been fabricated on a 3 axis milling machine using CAD / CAPP / CAM tools described in this paper. Examples of aluminum molds and sample output from the mold making agent are presented.

Dynamic In-Process Stock Based Tool Path Generation for High Surface Finish Rough Machining

2013 ◽  
Vol 567 ◽  
pp. 59-65
Author(s):  
Song Lin Ding ◽  
John P.T. Mo ◽  
Daniel Yang
Keyword(s):  
Surface Finish ◽  
Process Model ◽  
Tool Path ◽  
High Surface ◽  
Tool Path Generation ◽  
Path Generation ◽  
Rough Machining ◽  
Machining Time ◽  
Additional Tool ◽  
Tool Paths

This paper presents a new tool path generation strategy for rough machining based on the dynamic in-process stock model of the workpiece. Compared to conventional roughing method, the new tool paths result in a better surface finish but consume the same machining time. The cutter locations in the tool path are determined by removing the peak portion of the residual materials on the stock. The geometric information of remaining stocks is updated dynamically in the in-process model once each cutting pass is completed. The overall machining time is no longer than the conventional method since no additional tool paths are added. The proposed method was implemented in Catia and has been validated by simulation and cutting tests with flat end and ball nose cutters on a 3-axis CNC milling machine.

An Efficient and Economical Rapid-Tooling Method for Die-Sinking Electrical Discharge Machining

2011 ◽  
Vol 133 (5) ◽  
Author(s):  
Lin Gu ◽  
Lei Li ◽  
Wansheng Zhao ◽  
Kamlakar P. Rjaurkar
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Dielectric Fluid ◽  
Rough Machining ◽  
Electrode Gap ◽  
Machining Time ◽  
Cylindrical Cell ◽  
Tool Wear Ratio ◽  
Large Peak ◽  
Cell Electrode

This paper reports on the efficiency and economy of bundled electrode in die-sinking electrical discharge machining (EDM). Bundled electrode was fabricated by putting several thin tubular or cylindrical cell electrodes together and forming an approximate 3D end-face geometry by adjusting the length of each cell electrode. This method of electrode design and fabrication significantly reduced the fabrication time and cost compared to that of traditional cutting method. The bundled electrode allows better flushing of dielectric fluid to facilitate removal of more heat and debris from the inter electrode gap. Experiments were conducted to demonstrate the advantages of bundled electrode in rough machining with large peak current. It was also found that the relative higher tool wear ratio could be reduced by using graphite cell electrodes. Additionally, time and cost of tools preparation as well as the machining time between EDM with bundled electrode and solid die-sinking electrode were compared by machining a 3-blade cavity component.

Optimal CNC Plunger Selection and Toolpoint Generation for Roughing Sculptured Surfaces Cavity

2006 ◽  
Vol 128 (4) ◽  
pp. 1025-1029 ◽  
Author(s):  
Tawfik T. El-Midany ◽  
Ahmed Elkeran ◽  
Hamdy Tawfik
Keyword(s):  
Research Work ◽  
New Method ◽  
Path Generation ◽  
Sculptured Surfaces ◽  
Rough Machining ◽  
Plunge Milling ◽  
Machining Time ◽  
Selection Of

Plunge milling is among the most effective methods of deep core/cavity shaped rough machining techniques. Previous research work had not considered the optimization of plunger selection and toolpoint path. In this paper a new method is proposed (overlapped circles filling (Ocfill)) for optimizing the selection of plungers and toolpoint path generation. The proposed method is used to fill 2D area with a number of overlapped circles. The 2D area is expressed as the feature that being cutting with plunge milling and the circles are plunging holes. The Ocfill method has been implemented in Visual C++. The Ocfill is applied to many examples. The results show that, Ocfill saves rough machining time by significant value up to 28%. This value depends on the shape and complexity of the workpiece that is being cut.

scholarly journals Wall thickness determination study for a plastic injection barrell due to the internal pressure

2021 ◽  
pp. 10-15
Author(s):  
Jesús E. RODRÍGUEZ-DAHMLOW ◽  
David CONTRERAS-LOPÉZ ◽  
Rosalba FUENTES-RAMÍREZ ◽  
Luis E. MURILLO-YAÑEZ
Keyword(s):  
Wall Thickness ◽  
Factor Of Safety ◽  
Safety Margin ◽  
Injection Pressure ◽  
Machining Time ◽  
Injection Process ◽  
Different Types ◽  
Common Activity ◽  
Mechanical Elements ◽  
Plastic Injection

The use of Plastics is a very common activity nowadays, there are many different types of Injection Machines varying in size, the capacity of the material to inject, one of the main machines classifications is due to the injection pressure. One of the things to consider when the designing process is carried out is the factor of safety, this factor helps designers to avoid possible failures in mechanical elements of mechanisms, it provides a safety margin that aims to protect against any unexpected incident. The advantage of Simulation is that allows us to predict the behavior of elements under stress. In the Injection Process, barrels are elements subject to high pressure. This encourages analyzing wall thickness to find a suitable barrel wall thickness. The present study is focused on the design of the wall thickness, seeking reduce machining time that are required when producing the barrels that may be needed and to select the proper commercial barrel size reducing material waste.

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