Abstract
Form tools have been used in industry for a number of decades. Their use is booming and such growing popularity can be attributed to minimized manufacturing costs and shorter manufacturing time. On the other side, one of the major drawbacks is the method of their design. It reflects in the constraints present in the machining of straight-line and circular arc segments of a workpiece. For each segment the rake angle has a different value, which imposes an additional constraint. In case it is necessary to use form tools to manufacture complex-geometry parts, the value of the rake angle would require to be zero. The paper presents contemporary design method of circular form tools by implementing CAD system. This way, it is not only provided a constant value of the rake angle across the entire cutting edge, which can be different from zero too, but also optimum tool geometry for machining a desired material. Additionally, the geometry of a form tool designed using a new method was experimentally tested.
Highlights
In order to ensure the survival of products in the market under conditions of rapid growing competition, manufacturers are competing with each other to implement novel, more efficient and innovative production methods as early as possible
If more than one tool is used for machining a single part, the total machining time for that part will be considerably longer compared to the situation when one complex-geometry tool is used
The paper shows a new method for designing circular form tools by implementing commercial CAD system, whereby the tool form obtained has a constant rake angle across the entire cutting edge
Summary
In order to ensure the survival of products in the market under conditions of rapid growing competition, manufacturers are competing with each other to implement novel, more efficient and innovative production methods as early as possible. The inherent feature of each new production method is the reduction of the final product’s cost It can be achieved by minimizing the machining time, reducing use of resources and substituting for cheaper ones, automation of manufacturing process, etc. The paper shows a new method for designing circular form tools by implementing commercial CAD system, whereby the tool form obtained has a constant rake angle across the entire cutting edge. Another adva– ntage of this design method is the possibility of building a complex-geometry part, with the tool rake angle value different from zero or constant across the entire cutting edge. Scanning of the workpiece was the final check that implied inspection of the workpiece shape and dimensions
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