Study on Computer-Aided Process Planning of Mold Part Machining

Abstract

Large molds with very deep shape are used in producing bumpers and inner panels of automobiles. In order to realize the precise and stable machining of such deep molds, 3-axis milling with inclined cutters is often applied. Some machining regions are difficult to process with a cutter in a single orientation. Such regions must be subdivided into several smaller regions, so that each region can be processed with a single orientation cutter. We propose a new algorithm for automatically subdividing the machining region. A machining region is represented as a set of cubic blocks in our study. For each block, all accessible directions of a cutter are computed. Neighboring blocks with similar cutter accessible directions are then combined, and some groups of blocks with similar cutter accessible directions are obtained. Proposed algorithm is implemented and an experimental process planning assistance program using this technology is demonstrated.