Machining, Measurement, and Control Laboratory

Intelligent CAM System for Manufacturing of Die/Mold
Hirotoshi Ohtsuka (Oita Industrial Research Institute)
Yoshiaki Kakino (Kyoto University)
Iwao Yamaji (Kyoto University)
Atsushi Matsubara (Kyoto University)
Soichi Ibaraki (Kyoto University)
Heisaburo Nakagawa (The University of Shiga Prefecture)
Susumu Nishida (Manufacturing Technology Institute, Inc.)

An intelligent CAM system for manufacturing of die/mold has been developed by DBM Research Consortium. This system allows even inexperienced operators to successfully apply the method of direct endmilling of hardened steel using (Al,Ti)N-coated micro-grain carbide cutters for pre-finish cutting processes of die/mold. This system supports process design for rough and intermediate-rough cutting, decision of cutting conditions, and tool life estimation. Fixed cycles such as spiral, trochoid and corner machining are fully utilized in the proposed CAM system along with a feed rate adaptation strategy for constant cutting forces. They are applied mainly for removing critical regions in the tool path pattern. Those regions are characterized by an excessive cutting engagement and excessive cutting force. The intelligent CAM system was verified experimentally for rough and intermediate-rough machining in the case of manufacturing a cavity-type mold. The system achieved good results with regard to productivity and costs.