Milling simulation for process optimization in the field of die and mould manufacturing

摘要

when milling sculptured surfaces the major problems are the limited precision due to milling-cutter deflections caused by the cutting force and a unsatisfactory process reliability. One method for improving surface quality while maintaining highprocess reliability is the computer-based engagement analysis and feed-rate adaptation. The aim of the feed-rate adaptation is to avoid intolerably high tool loads as they occur while semi-finishing sculptured surfaces. The method developed uses anefficient, volume model to simulate the cutting process. The calculation of the optimal feed-rate takes the main technological aspects of 3-axis milling into account. The efficiency of the approach developed is demonstrated with a practical example.