模具设计与制造 外文文献翻译 英文原文 word版 manufacturing of dies and molds

MANUFACTURINGOFDIESANDMOLDSTAYLANALTAN,BLAINELILLG,YCYENABSTRACTTHEDESIGNANDMANUFACTURINGOFDIESANDMOLDSREPRESENTASIGNIFICANTLINKINTHEENTIREPRODUCTIONCHAINBECAUSENEARLYALLMASSPRODUCEDDISCRETEPARTSAREFORMEDUSINGPRODUCTIONPROCESSESTHATEMPLOYDIESANDMOLDSTHUS,THEQUALITY,COSTANDLEADTIMESOFDIESANDMOLDSAFFECTTHEECONOMICSOFPRODUCINGAVERYLARGENUMBEROFCOMPONENTS,SUBASSEMBLIESANDASSEMBLIES,ESPECIALLYINTHEAUTOMOTIVEINDUSTRYTHEREFORE,DIEANDMOLDMAKERSAREFORCEDTODEVELOPANDIMPLEMENTTHELATESTTECHNOLOGYINPARTANDPROCESSDESIGNINCLUDINGPROCESSMODELING,RAPIDPROTOTYPING,RAPIDTOOLING,OPTIMIZEDTOOLPATHGENERATIONFORHIGHSPEEDCUTTINGANDHARDMACHINING,MACHINERYANDCUTTINGTOOLS,SURFACECOATINGANDREPAIRASWELLASINEDMANDECMTHISPAPER,PREPAREDWITHINPUTFROMMANYCIRPCOLLEAGUES,ATTEMPTSTOREVIEWTHESIGNIFICANTADVANCESANDPRACTICALAPPLICATIONSINTHISFIELDKEYWORDSDIE,MOLD,MANUFACTURING0INTRODUCTIONTHEAUTHORSWOULDLIKETOTHANKALLOFTHECOLLEAGUESWHORESPONDEDTOTHEREQUESTFORINFORMATIONINPREPARINGTHISREVIEWPAPER,NAMELYTOPROFKLOCKEWZLAACHEN,PROFTONSHOFFIFWHANNOVER,PROFWERTHEIMISCAR,LTDISRAEL,PROFSKRUTHANDLAUWERSCATHOLICUNIVERSITYLEUVEN,PROFRASCHNTNUTRONDHEIM,PROFGEIGERANDRENGELLFTERLANGEN,PROFWEINERTISFDORTMUND,RLEOPOLDGFECHEMNITZ,MRREZNICKEXTRUDEHONECORP,PROFGUNASEKERAOHIOUNIVERSITY,PROFBRAMLEYUNIVERSITYOFBATH,PROFBUENOFUNDACIONTEKNIKER,PROFNEUGEBAUERANDDRLANGFRAUNHOFERIWUCHEMNITZTHANKSAREALSODUETOOURCOWORKERSANDTHEERC/NSM,ASWELLASTHECOWORKERSOFPROFKLOCKEATWZL,ANDOFPROFTONSHOFFATIFW,WHOASSISTEDUSINCOLLECTINGTHEREFERENCESANDINTHEPREPARATIONOFFIGURESFURTHERMORE,WEAPPRECIATETHERESPONSETHATWERECEIVEDFROMMANYOFTHEPARTICIPANTSOFTHE2001MOLDMAKINGCONFERENCE1BACKGROUNDPRODUCTIONOFINDUSTRIALGOODSREQUIRESMANUFACTURINGOFDISCRETEPARTSTHATARESUBASSEMBLEDANDASSEMBLEDTOAPRODUCTREADYFORTHECUSTOMERTHEMANUFACTURINGOFNEARLYALLMASSPRODUCEDDISCRETEPARTSREQUIREDIESANDMOLDSTHATAREUSEDINPRODUCTIONPROCESSESSUCHASFORGING,STAMPING,CASTING,ANDINJECTIONMOLDINGTHUS,THEDESIGNANDMANUFACTURINGOFDIESANDMOLDSREPRESENTAVERYCRUCIALASPECTOFTHEENTIREPRODUCTIONCHAINTHISCANBEILLUSTRATEDBYTHEFOLLOWINGOBSERVATIONSDIESANDMOLDS,SIMILARTOMACHINETOOLS,MAYREPRESENTASMALLINVESTMENTCOMPAREDTOTHEOVERALLVALUEOFANENTIREPRODUCTIONPROGRAMHOWEVER,THEYARECRUCIAL,ASAREMACHINETOOLS,INDETERMININGLEADTIMES,QUALITYANDCOSTSOFDISCRETEPARTSMANUFACTURINGANDTRYOUTOFNEWDIESANDMOLDSMAYBECRITICALINDETERMININGTHEFEASIBILITYANDLEADTIMEOFANENTIREPRODUCTIONPROGRAMFOREXAMPLE,INMANUFACTURINGAUTOMOTIVEINTERIORCOMPONENTSBYINMOLDLAMINATIONCOMPLEXMOLDSTHATAREUSEDMAYCOSTUPTO05MILLIONANDREQUIRE6TO9MONTHSFORTRYOUTANDROBUSTPROCESSDEVELOPMENTUSINGPRODUCTIONEQUIPMENTCONSIDERINGTHATTHEOEMSREQUIRESAMPLEPARTS,PRODUCEDONPRODUCTIONEQUIPMENTNOTPROTOTYPES,6TO9MONTHSPRIORTOSTARTOFPRODUCTIONSOPOFANEWCARMODEL,THESIGNIFICANCEOFMOLDMAKINGBECOMESOBVIOUSTHEQUALITYOFTHEDIESANDMOLDSDIRECTLYAFFECTTHEQUALITYOFTHEPRODUCEDPARTSEXCELLENTEXAMPLESAREMOLDSUSEDFORINJECTIONMOLDINGLENSES,ORDIESUSEDFORPRECISIONFORGINGOFAUTOMOTIVEDRIVETRAINCOMPONENTS11SIGNIFICANCEOFTHETECHNOLOGYTHEOBSERVATIONSLISTEDABOVEILLUSTRATETHATDIEANDMOLDMAKINGHASAKEYPOSITIONINMANUFACTURINGCOMPONENTSINVIRTUALLYALLINDUSTRIESBUTESPECIALLYINTRANSPORTATION,CONSUMERELECTRONICSANDCONSUMERGOODSINDUSTRIESTHEEFFECTIVENESSOFDIEMAKINGAFFECTSTHEENTIREMANUFACTURINGCYCLESOTHATTHISTECHNOLOGYMUSTBECONSIDEREDTOBEAVERYESSENTIALLINKINTHETOTALPRODUCTIONCHAINDIEANDMOLDMAKINGCOVERSABROADRANGEOFACTIVITIES,INCLUDINGAMANUFACTURINGOFNEWDIESANDFIXTURES,BMAINTENANCEANDMODIFICATIONS,ANDCTECHNICALASSISTANCEANDPROTOTYPEMANUFACTURINGFORTHECUSTOMER,FIGURE11,PROCESSDEVELOPMENTANDDIETRYOUTASWELLASDIEMAINTENANCEAREESPECIALLYIMPORTANTBECAUSETHEYTIEUPEXPENSIVEPRODUCTIONEQUIPMENTANDAFFECTLEADTIMESTHESEACTIVITIESMUSTBESCHEDULEDANDCOMPLETEDWITHINVERYRIGIDDEADLINESSUCHREQUIREMENTSMAKESCHEDULINGINADIESHOPANEXTREMELYCHALLENGINGTASKTHEAUTOMOTIVEINDUSTRYCONSTANTLYTRIESTOREDUCETHEDEVELOPMENTTIMEFORNEWMODELSWHICHPUTSENORMOUSPRESSUREONDIEMAKERSANDREQUIRESNEWPRODUCTIONSYSTEMS2,12VARIETYOFDIESANDMOLDSTHEFOURMAJORPROCESSESTHATUTILIZEDIESANDMOLDSAREQUIREDIFFERENTTECHNOLOGIESFORDESIGNANDPRODUCTION,ANDBUTILIZEDIFFERENTTERMINOLOGIES,FIGURE23,FOREXAMPLE,DIECASTINGDIESHAVEMOREDEEPANDTHINRIBCAVITIESTHATCANNOTBEEASILYMACHINEDTHANINJECTIONMOLDINGMOLDSASARESULTFIVETIMESMOREPLUNGEEDMMACHINESAREUSEDINTHEDIECASTINGINDUSTRYTHANINTHEINJECTIONMOLDINGINDUSTRYANOTHEREXAMPLEISTHEEXTENSIVE,NEARLY50,USEOFWIREEDMMACHINESFORMAKINGBLANKINGDIESWHILEONLY5OFTHESEMACHINESAREUSEDTOMAKEEXTRUSIONDIESASSEENINFIGURE2,LARGEDEEPDRAWINGANDSTAMPINGDIESAREMADEBYMACHININGCASTIRONORSTEELSTRUCTURESWHILEDIESFORFORGING,DIECASTINGANDPLASTICSMOLDINGAREMADEFROMTOOLSTEELBLOCKS,INVOLVINGCONSIDERABLEROUGHMACHININGOPERATIONSINJECTIONMOLDINGMOLDSANDDIECASTINGDIESALLOWTHEPRODUCTIONOFRATHERCOMPLEXPARTSWITHUNDERCUTSAND/ORHOLLOWGEOMETRIESTHUS,THESETOOLSUSUALLYHAVEMULTIPLEMOTIONSLIDESANDPUNCHESASWELLASCOOLINGCHANNELSTHATCOMPLICATETHEMANUFACTURINGPROCESSDIESANDMOLDSARECOMPOSEDOFFUNCTIONALCAVITY,COREINSERT,PUNCHANDSUPPORTCOMPONENTSGUIDEPINS,HOLDER,DIEPLATEOFTENSUPPORTCOMPONENTSANDANUMBEROFHOLESNEEDONLY2DOR2DMACHINING,BUTMAYREQUIRE50TO60OFTHETOTALMANUFACTURINGTIMETHISFACTISOFTENNEGLECTEDBUTMUSTBECONSIDEREDINEFFECTIVEPLANNINGOFTHEMACHININGOPERATIONSWHILEMETALCUTTINGANDEDMARETHEMAJORMETHODSUSEDFORDIEANDMOLDMAKING,HOBBING,MICROMACHININGANDCHEMICALETCHINGMETHODSAREALSOUSEDFORMANUFACTURINGMOLDSFORVARIOUSAPPLICATIONSPRODUCTDESIGNDEVELOPMENTPROCESSLAYOUTDIEIMOLDDEVELOPMENTDIEIMOLDMANUFACTURINGTRYOUT,ASSEMBLY,USEANDRECYCLING3DCADPROCESSSIMULATIONPROCESSSIMULATIONLASERCUTTINGFEMSIMULATIONRAPIDTOOLINGCADICAMSYSTEMSENDASSEMBLYVIRTUALPROTOTYPINGREVERSEENGINEERINGMACHININGSTRATEGYQUALITYCONTROLRAPIDPROTOTYPINGSIMULTANEOUSENGINEERINGDIE/MOLDDEVELOPMENTFORROBUSTPROCESSREVERSEENGINEERINGFEATUREBASEDOUTLINEOFPROCESSCHAINSIMULTANEOUSENGINEERINGFIGURE1POSITIONOFDIEANDMOLDMACHININGINPRODUCTLIFECYCLE1,13ECONOMICSOFDIE/MOLDMAKINGACCORDINGTOARECENTSURVEY4,MAJORISSUESTHATFACEDIEANDMOLDMAKERSARESIMILARINALLINDUSTRIALIZEDCOUNTRIES,NAMELY1DECLININGPRICESANDPROFITMARGINSSOTHATTHEREISASTRONGNEEDTOCONTROLANDREDUCECOSTS2DEMANDSFORBUILDINGDIES/MOLDSINFARLESSTIMENEARLY50LESSTHANBEFORE3NEEDFOREXTENDEDCUSTOMERSERVICEDATAHANDLING,ADVICE,PROTOTYPEPARTS,ASSISTANCEINPROCESSDEVELOPMENT4LACKANDCOSTOFSKILLEDLABOR,WHICHLEADSTOTHENEEDTOPROVIDEEXTENSIVETRAININGTOEMPLOYEESANDTOUTILIZE“NEWTECHNOLOGIES“5GLOBALIZATIONTHATLEADSTOINCREASEDFOREIGNCOMPETITION,ESPECIALLYFROMDEVELOPINGCOUNTRIESWHERESKILLLEVELSAREINCREASINGWHILESALARIESARECOMPARATIVELYLOWPRIORITIESDIFFERACCORDINGTOCOUNTRIESSURVEYEDFOREXAMPLEWHILENORTHAMERICANANDGERMANMOLDMAKERSAREMAINLYCONCERNEDWITHFOREIGNCOMPETITION,JAPANESECOMPANIESCONCENTRATEONDEVELOPINGNEWMARKETSINALLCOUNTRIES,HOWEVER,THEACCEPTANCEOF“NEWTECHNOLOGIES“ISRECOGNIZEDTOBEONEESSENTIALCOMPONENTTHATCANLEADTOINNOVATIONANDINTEGRATIONTHATAREESSENTIALFORGROWTH5NEWTECHNOLOGIESAREUNDERSTOODTOINCLUDENOTONLYMANUFACTURINGTECHNIQUESHIGHSPEEDMILLING,HARDMACHINING,AUTOMATION,PROCESSMODELING,ETCBUTALSOPREANDPOSTMANUFACTURING,EGCOSTESTIMATINGANDCONTROL,DOCUMENTATION,TRAININGANDOPERATIONSMANAGEMENTTHUS,TWOESSENTIALCOMPONENTSFORACHIEVINGACOMPETITIVEPOSITIONINDIE/MOLDINDUSTRYAREACAPABILITIESOFPERSONNEL,ANDBUTILIZATIONOFOPTIMIZEDANDINNOVATIVEPRODUCTIONTECHNIQUES6,BOUNDARYCONDITIONSBLANKINGTOOLSMATERIALX155CRVMO121HIGHGEOMETRICRATIOHS653PMSMALLGEOMETRIESANDTHINFEATURESHMK40HIGHQUALITYREQUIREMENTSHARDNESS5763HRCPRODUCTIONTHROUGHWIREEDMORCOORDINATEPROFILEGRINDINGINJECTIONMOLDINGMOLDSANDDIECASTINGDIESMATERIALHIGHDEPTH/SMALLRADII40CRMNMO7VERYHIGHQUALITYREQUIREMENTSX38CRMOV51USEOFTHINANDLONGMILLINGCUTTERSTENSIIESTRENGTHR,10001500N/MIRFHIGHDEMANDSONSPINDLERPMANDCONTROLLERPERFORMANCEHARDNESS4858HRCMILLINGANDEDMDEEPDRAWINGDIESMATERIALFLATGEOMETRIES1BIGRADIIGG25CRMOUNKNOWNMACHININGALLOWANCESGGG70ZAMAKHIGHDEMANDSONSPINDLERPMFEEDRATEANDCONTROLLERPERFORMANCEHARDNESS220270H830GRAYCASTIRONFULLMACHININGTHROUGHMIILINGPOSSIBLEFIGURE2WORKPIECECHARACTERISTICSINDIEANDMOLDMAKING3,SUCCESSFULDIE/MOLDMAKERSRECOMMENDTHAT,FORAFINANCIALLYSUCCESSFULDIEMAKINGOPERATION,ITISNECESSARYTO1ESTABLISHQUANTITATIVEMETHODSFORCOSTESTIMATINGINTHISINDUSTRYCOSTESTIMATESAREOFTENBASEDONTHE“PASTEXPERIENCE“AND“FEEL“OFTHEDIEMAKERANDCOMPARISONWITH“SIMILAR“DIESASARESULTTHEACCURACYOFTHEESTIMATIONS,THATMAYDETERMINEPROFITORLOSS,MAYBEINTHERANGEOF207,2DETERMINETHEENTIREPROCESSCHAINFORDIEMAKING,FROMINQUIRYUNTILDELIVERYTOTHECUSTOMER3IDENTIFYALLCOSTPARAMETERSANDQUANTIFYCOSTFACTORS,EVENTUALLYBYREVIEWINGPASTHISTORYDATACOLLECTIONFORWORKINGHOURS,CONTRACTS,COSTACCOUNTING4ESTABLISHACONTRACTUALBASISSOTHATITEMSNONSPECIFIEDINTHECONTRACTAREONLYPROVIDEDATEXTRACHARGE8,INORDERTOMAINTAINDEADLINES,FOCUSONCONTRACTINITIALIZATIONANDNOTONASSEMBLYOFTHEMOLD,WHERECONSIDERABLEMANPOWERISINVOLVEDANDITISDIFFICULTTOCHANGEASCHEDULE5PROVIDESERVICESTOTHECUSTOMERMAINLYINDATAMANAGEMENTATTHESTARTANDDURINGPRODUCTIONBUTALSODURINGPROCESSDEVELOPMENTWITHCOMPLEXMOLDSTHATMAYREQUIRECONSIDERABLETRYOUTTIMEFORSUCCESSFULDIEMAKERSQUALITYISAGIVENTHETIMEFORWORKINPROGRESS,ORSTORAGETIME,CANBEASIGNIFICANTFACTORINLOWVOLUMEPRODUCTION,SUCHASDIE/MOLDMAKINGINTHISAPPLICATIONITISESTIMATEDTHAT70OFTHE“TOTALPRODUCTIONTIME“CONSISTSOFSTORAGETIMEWHENNOVALUEISADDEDTOTHEPRODUCTTHISSITUATIONCANONLYBEIMPROVEDBYINCREASINGMACHININGCAPACITY,MACHINEUTILIZATIONRATE,OR/ANDIMPROVINGTHEEFFICIENCYOFTHEPARTHANDLINGOPERATIONS9,TOREDUCETHETIMEFORWORKINPROGRESS,MANYHIGHTECHNOLOGYDIESHOPSHAVESEPARATEDTOOLPATHGENERATIONFROMENGINEERINGANDDESIGNOFTHEDIESWHILETHELATTERISDONEINTHEENGINEERINGDEPARTMENT,TOOLPATHGENERATIONISDONEONTHESHOPFLOORBYTHEMACHINEOPERATOR2PART,DIEANDPROCESSDESIGNFIGURE3PROLIFERATIONOFCADSYSTEMSINSUPPLYCHAIN10,INMANUFACTURINGDISCRETEPARTSUSINGDIESORMOLDS,THEPARTDESIGNMUSTBECOMPATIBLEWITHTHEPROCESSINORDERTOASSURETHEPRODUCTIONOFHIGHQUALITYPARTSATLOWCOSTWITHSHORTLEADTIMESTHUS,PARTANDPROCESSDESIGNSAREBESTCONSIDEREDSIMULTANEOUSLY,WHICHISOFTENNOTTHECASEINPRACTICETHISOBJECTIVECANONLYBEACHIEVEDTHROUGHGOODCOMMUNICATIONBETWEENTHEPRODUCTANDTOOLDESIGNER,WHOMAYBEINDIFFERENTCOMPANIESOEMANDSUPPLIERAND/ORLOCATIONSTHEUSEOFDIFFERENTCADSYSTEMSBYOEMSANDSUPPLIERSFURTHERCOMPLICATESCOMMUNICATIONWITHINTHESUPPLYCHAINFIGURE3,TAKENFROM10,SHOWSTHEPROLIFERATIONOFCADSYSTEMSINTHETOPTHREETIERSOFTHENORTHAMERICANAUTOMOBILEINDUSTRYBECAUSEDIEANDMOLDMAKINGFIRMSTENDTOBETHIRDORFOURTHTIERSUPPLIERS,THE“INTEROPERABILITYPROBLEM“OFRELIABLYTRANSFERRINGCADDATABETWEENFIRMSISPARTICULARLYACUTEINTHISINDUSTRYITISWELLKNOWNTHATTHEDESIGNACTUALLYREPRESENTSONLYASMALLPORTION,5TO15,OFTHETOTALPRODUCTIONCOSTOFAPARTHOWEVER,DECISIONSMADEATTHEDESIGNSTAGEHAVEAPROFOUNDEFFECTUPONMANUFACTURINGANDLIFECYCLECOSTSOFAPRODUCTINADDITIONTOSATISFYINGTHEFUNCTIONALREQUIREMENTS,THEPARTDESIGNMUSTCONSIDERATHESELECTEDMANUFACTURINGPROCESSANDITSLIMITATIONS,BEQUIPMENTANDTOOLINGREQUIREMENTS,CPROCESSCAPABILITIESSUCHASSIZE,GEOMETRY,TOLERANCES,ANDPRODUCTIONRATE,ANDDPROPERTIESOFTHEINCOMINGMATERIALUNDERPROCESSINGCONDITIONSOFTENTHEDESIGNREQUIRESDEVELOPMENTOFANEWTOOLINGAND/ORMODIFICATIONOFANEXISTINGPROCESSINSUCHCASESDIE/MOLDDEVELOPMENTANDTRYOUTCANTAKEASLONGOREVENLONGERTHATTHETIMENEEDEDFORDIEMANUFACTURINGTHEASSEMBLYREADYPARTGEOMETRY,USUALLYINELECTRONICFORM,MUSTBEUSEDTODEVELOPTHEDIEORMOLDGEOMETRIESASWELLASTOSELECTTHEPROCESSPARAMETERSFIGURE4ILLUSTRATES,USINGFORGINGASANEXAMPLE,THEFLOWOFINFORMATIONANDACTIVITIESINCOMPUTERAIDEDDIEANDPROCESSDESIGN11,PROCESSESSUCHASSTAMPING,HOTANDCOLDFORGINGMAYREQUIRESEVERALOPERATIONSSTARTINGWITHTHEINITIALSIMPLEBILLETORSHEETBLANKUNTILTHEFINISHFORMEDPARTISOBTAINEDTHUS,SEVERALDIESETSMAYBENEEDEDINPROCESSES,WHERETHEINCOMINGMATERIALISSHAPELESS,EGPOWDERCOMPACTION,INJECTIONMOLDING,DIECASTING,ASINGLESETOFDIESORMOLDSHAVETOBEDESIGNEDDIEDESIGNISESSENTIALLYANEXPERIENCEBASEDACTIVITYHOWEVER,ITISENHANCEDSIGNIFICANTLYBYUTILIZINGPROCESSMODELINGTECHNIQUESTO1ESTIMATEMATERIALFLOWANDDIESTRESSES2ESTABLISHOPTIMUMPROCESSPARAMETERSMACHINEANDRAMSPEED,DIE/MOLDANDMATERIALTEMPERATURES,TIMEFORHOLDINGUNDERPRESSURE,ETC3DESIGNDIE/MOLDFEATURES,NECESSARYTOPERFORMTHEPROCESSFLASHANDDRAFTINFORGING,BINDERSURFACEANDDRAWBEADSINSTAMPING,GATESANDRUNNERSININJECTIONMOLDINGANDDIECASTING4FINALIZETHEPRODUCTANDDIEDIMENSIONSBYPREDICTINGANDELIMINATINGDEFECTSWHILEADJUSTINGTHEPROCESSPARAMETERSFOROBTAININGAROBUSTPROCESSTHEAPPLICATIONOFPROCESSMODELING,USING3DFEMBASEDSOFTWARE,ISNOWCONSIDEREDROUTINEINIPERMANENTMOLDANDDIECASTING,IIINJECTION,GASINJECTION,COMPRESSIONANDBLOWMOLDING,ANDIIISHEETMETALFORMINGINFORGING,WHILE2DSIMULATIONISWIDELYPRACTICED,3DAPPLICATIONSAREBEINGINTRODUCEDBYADVANCEDTECHNOLOGYCOMPANIESRESEARCHISBEINGCONDUCTEDONA“REVERSESIMULATIONAPPROACH“FORDESIGNINGFORGINGPREFORMS12,EXAMPLESOFFEMSIMULATIONRESULTSARESEENINFIGURE5FORFORGINGANDFIGURE6FORSTAMPING11,APPLICATIONOF2DFEMSIMULATIONINMETALCUTTINGISNOWBEINGINTRODUCEDBYMANYCOMPANIESBUTITISSTILLINTHER15M/MINORHIGHERWHENAPPROPRIATEPRESSUREDAIRORCOOLANTMISTISPROVIDED,USUALLYTHROUGHTHESPINDLESPINDLERPM10,000TO50,000DEPENDINGUPONTOOLDIAMETERSURFACECUTTINGSPEEDS300M/MINTO1000M/MIN,DEPENDINGUPONTHEHARDNESSOFTHEDIE/MOLDSTEELANDTHECHIPLOADHIGHSPEEDCONTROLWITHHIGHSPEEDDATAANDLOOKFORWARDCAPABILITYTOAVOIDDATASTARVATIONLOOKFORWARDCAPABILITYTRACKSSURFACEGEOMETRY,ALLOWINGTHEMACHINETOACCELERATEANDDECELERATEEFFECTIVELYFORMAINTAININGTHEPRESCRIBEDSURFACECONTOURHIGHACCELERATIONANDDECELERATIONCAPABILITIESOFTHEMACHINETOOLINTHERANGEOF08TO12M/S243MACHININGOFDIESFORSHEETMETALSTAMPINGLARGEDIESFORSHEETMETALFORMINGAREMANUFACTUREDBYROUGHANDFINISHMACHININGCASTIRONORSTEELDIESTRUCTURESINMACHININGOFCASTIRON,COATEDCARBIDES,CBN,SINANDCOATEDCARBIDESARETHEMOSTCOMMONLYUSEDTOOLSRECENTLY,THEPERFORMANCEOFVARIOUSCBNGRADESANDCOATEDCARBIDESWEREINVESTIGATED44,MILLINGEXPERIMENTSWEREPERFORMEDONAFOURAXISHIGHSPEEDHORIZONTALMILLINGCENTERTOOLGEOMETRYANDCUTTERSPECIFICATIONSAREGIVENINFIGURE15USINGTINCOATEDCARBIDETOOLSINSTEADOFUNCOATEDCARBIDETOOLSINCREASESPRODUCTIVITYINTERMSOFCUTTINGSPEEDBY25WHILETOOLLIKEINCREASESBYMORETHAN500INADDITION,TIAINCOATEDINSERTSRANATLEASTTHREETIMESASLONGASTINORTICNCOATEDINSERTSATANYCUTTINGSPEED,FIGURE16HOWEVER,PCBNINSERTSOUTPERFORMEDTHECOATEDCARBIDEINSERTSTESTSWEREABORTEDAFTERA16MOFSURFACEAREAWASMACHINEDANDTOOLWEARONPCBN2WASMEASUREDATVBMAX60ANDONPCBN0ATVBMAX85ABRASIONANDTHERMALFATIGUEWEREIDENTIFIEDASTHEMAINWEARMECHANISMSHIGHERCBNCONTENTANDHIGHERHARDNESSEXHIBITEDFAVORABLEWEARRESISTANCE44MACHININGOFDIESANDMOLDSFROMATOOLSTEELBLOCKFIGURE15TOOLGEOMETRYANDTOOLLIFECRITERIONUSEDFORTHECUTTINGTOOLS44,INGENERALMOLDSFORINJECTIONMOLDING,BLOWMOLDINGANDCOMPRESSIONMOLDING,ASWELLASDIESFORDIECASTING,FORGINGANDTUBEHYDROFORMING,AREMANUFACTUREDFROMABLOCKOFTOOLSTEELINEXCEPTIONALCASESMOLDSAREALSOMADEFROMALUMINUMORCOPPERALLOYSINTHESEAPPLICATIONSALARGEAMOUNTOFMATERIALMUSTBEREMOVEDBYROUGHMACHININGCONSEQUENTLY,MACHINABILITYOFTOOLSTEEL,TOGETHERWITHMANYDIFFERENTASPECTSOFHARDANDHSCMILLING,ISANIMPORTANTISSUE,ESPECIALLYFORROUGHMACHININGINARECENTSTUDY,THEMACHINABILITYOFTHREEMOLDSTEELSWITHDIFFERENTSULFURCONTENTSBUTOFTHESAMEHARDNESSHB300WASINVESTIGATEDBYVARYINGTHECUTTINGCONDITIONS31,ITWASFOUNDTHATATHEMAINPARAMETERSAFFECTINGTHEMILLINGPROCESSUSINGROUNDCARBIDEINSERTINA40MMTORUSTOOLWERECUTTINGVELOCITY,FEEDPERTOOTHANDRADIALANDAXIALDEPTHSOFCUT,BTHEADDITIONOFSULFURTOTHEMOLDSTEELBRINGSANINCREASEOFABOUT50INTOOLLIFE,ANDCWHENMACHININGATHIGHFEEDRATESANINCREASEOF75INTOOLLIFECOULDBEOBTAINEDFUNDAMENTALSOFHIGHSPEEDANDHARDMACHININGARESTILLPARTIALLYUNDERSTOODRESEARCHISBEINGCONDUCTEDINVARIOUSLABORATORIESTOUNDERSTANDTHEBASICPHYSICALPHENOMENATHATDETERMINESCHIPFORMATION,THEEFFECTOFCUTTINGSPEEDANDTEMPERATURESINMACHININGHARDENEDSTEELS,WITHINCREASINGCUTTINGSPEEDTHECHIPFORMATIONCHANGESFROMCONTINUOUSTOSERRATEDCHIPFORMTHUS,THECUTTINGFORCESMAYBEREDUCEDANDTOOLLIFEMAYBEINCREASEDPROVIDEDTHETEMPERATURESATTHETOOLEDGECANBEMAINTAINEDWITHINALLOWABLELIMITS45,EVALUATIONOFTHECUTTINGPOWERINFUNCTIONOFCUTTINGSPEED100TO3000M/MINSHOWEDTHATTHERESEEMSTOBEAMATERIALSPECIFICCUTTINGSPEEDWHERETHECUTTINGPOWERREACHESITSMAXIMUMVALUEBEYONDTHISVALUE,WITHINCREASINGSPEEDANEXCELLENTEXAMPLEOFHSCMILLINGOFHARDENEDDIESISDISCUSSEDINARECENTSTUDY47,THEINVESTIGATIONWASFOCUSEDONDIESFORFORGINGTURBINEANDCOMPRESSORBLADESDIEMATERIAL12343HEATTREATEDTO53HRCWITHANULTIMATESTRENGTHOF1600N/MM2THATHADSURFACEDIMENSIONSOF185125MMAND600330MMTHERESULTSOFTHISINVESTIGATIONILLUSTRATESMANYASPECTSOFHSCMILLINGFACEDININDUSTRIALPRACTICE,NAMELYDIEANDMOLDMAKERSAREPROVIDEDWITHALARGEAMOUNTOFINFORMATIONONTESTRESULTSONTOOLLIFEHOWEVER,THISINFORMATIONISDIFFICULTTOAPPLYTOTHESPECIFICCONDITIONSWITHOUTKNOWINGTHEEXACTTESTCONDITIONS,IEFEED,SPEED,INFEED,ANGLEOFINCLINATION,ETCTOSUCCEEDINTHEAPPLICATIONOFHSCMILLING,TEAMWORKCOOPERATIONBETWEEN3DDESIGNENGINEERS,NCMILLOPERATORSANDDOCUMENTATIONINADDITIONTOPROGRAMDOCUMENTATIONTHISINCLUDESMILLINGSTRATEGIES,MILLINGMACHINEANDOPERATIONPARAMETERSANDTESTRESULTSAREESSENTIALITISIMPORTANTTOINVESTMOREENGINEERINGTIMECALCULATIONS,PROGRAMMINGATTHESTARTOFMANUFACTURINGANEWDIETODETERMINETHE“BEST“MACHININGCONDITIONSTHUS,ITISPOSSIBLENOTTOREMAINCONSERVATIVEANDUSELOWFEEDRATESRESULTINGINLONGMACHININGTIMESINROUGHMACHININGITISBETTERTOUSERELATIVELYSMALLERTOOLDIAMETERSANDINCREASEDFEEDRATESTHUS,MOREUNIFORMMACHININGALLOWANCEISLEFT,WHICHFACILITATESFINISHMILLINGASARESULTTHETIMENECESSARYFORROUGHINGMAYINCREASEBUTTHETIMENEEDEDFORFINISHINGWILLDECREASESOTHATTHETOTALMILLINGTIMEMAYBEREDUCEDROUGHMACHININGPREHARDENEDDIEBLOCKSREQUIRESMORETIMETHANMACHININGINTHESOFTSTATEHOWEVER,WHENROUGHANDFINISHMACHININGINHARDENEDSTATE,ANEWTOOLSETUPISELIMINATEDWHILETHEDECISIONFORHARDMACHININGHASTOBEMADEFOREACHAPPLICATIONINDIVIDUALLY,INTHEPRESENTCASEHSCMILLINGINHARDENEDSTATECOULDBEDONEECONOMICALLYFORBOTHROUGHANDFINISHMACHINING,USINGFULLCARBIDEBALLENDMILLSANDINSERTS,FIGURE17THECUTTINGFORCEREMAINSAPPROXIMATELYCONSTANTANDTHEPOWERINCREASESLINEARLYWITHTHECUTTINGSPEED46,FIGURE16SUMMARYOFALLTOOLLIFEEXPERIMENTSINPEARLITICCASTIRONSYMBOLSEXPLAINEDINFIGURE1544,THISEXPERIENCEISVERYSIMILARTOTHATOFMANYADVANCEDTECHNOLOGYFORGINGSHOPSINNORTHAMERICAANDINJAPANTOINCREASEWEARRESISTANCEANDDIELIFE,FORGINGDIESAREOFTENSURFACEWELDEDWITHHIGHTEMPERATUREALLOYSINTHEPAST,THEFINISHINGOFSUCHSURFACEWELDEDDIES,NEWORAFTERREPAIR,WASDONEBYEDMRECENTLY,SPECIFICALLYDESIGNEDCUTTERSWITHPCBNINSERTSWEREUSEDFORHIGHSPEEDMACHININGOFSUCHWELDEDSURFACES48,39,STUDIESWITHDIFFERENTCUTTERMATERIALSDEM