Optimised process planning for re-contouring of repair-welded tool moulds by using a specific force model

Abstract

In the repair process of tool moulds, detected damages are removed and the resulting cavities are filled up by a welding process. Due to different types of damage and unknown weld seam properties, each repair case requires an individual machining strategy to ensure high quality. The re-machining step, so-called re-contouring, is currently very time-consuming and leads to experience-dependent workpiece quality. Therefore, this paper presents a specific Kienzle force model combined with optimisation strategies to adapt process parameters and toolpaths as a part of an automated re-contouring process flow. Based on experimental investigations, the force model is generated and used in a material removal simulation to predict the cutting forces according to the local cutting conditions. The method will be validated by re-contouring experiments with welded workpieces.