Mold Feature Recognition using Accessibility Analysis for Automated Design of Core, Cavity, and Side-Cores and Tool-Path Generation of Mold Segments

Injection molding is widely used to manufacture plastic parts with good surface finish, dimensional stability and low cost. The common examples of parts manufactured by injection molding include toys, utensils, and casings of various electronic products. The process of mold design to generate these complex shapes is iterative and time consuming, and requires great expertise in the field. As a result, a significant amount of the final product cost can be attributed to the expenses incurred during the product’s design. After designing the mold segments, it is necessary to machine these segments with minimum cost using an efficient tool-path. The tool-path planning process also adds to the overall mold cost. The process of injection molding can be simplified and made to be more cost effective if the processes of mold design and tool-path generation can be automated. This work focuses on the automation of mold design from a given part design and the automation of tool-path generation for manufacturing mold segments. The hypothesis examined in this thesis is that the automatic identification of mold features can reduce the human efforts required to design molds. It is further hypothesised that the human effort required in many downstream processes such as mold component machining can also be reduced with algorithmic automation of otherwise time consuming decisions. Automatic design of dies and molds begins with the part design being provided as a solid model. The solid model of a part is a database of its geometry and topology. The automatic mold design process uses this database to identify an undercut-free parting direction, for recognition of mold features and identification of parting lines for a given parting direction, and for generation of entities such as parting surfaces, core, cavity and side-cores. The methods presented in this work are analytical in nature and work with the extended set of part topologies and geometries unlike those found in the literature. Moreover, the methods do not require discretizing the part geometry to design its mold segments, unlike those found in the literature that result in losing the part definition. Once the mold features are recognized and parting lines are defined, core, cavity and side-cores are generated. This work presents algorithms that recognize the entities in the part solid model that contribute to the design of the core, cavity and side-cores, extract the entities, and use them in the design of these elements. The developed algorithms are demonstrated on a variety of parts that cover a wide range of features. The work also presents a method for automatic tool-path generation that takes the designed core/cavity and produces a multi-stage tool-path to machine it from raw stock. The tool-path generation process begins by determining tool-path profiles and tool positions for the rough machining of the part in layers. Typically roughing is done with large aggressive tools to reduce the machining time; and roughing leaves uncut material. After generating a roughing tool-path for each layer, the machining is simulated and the areas left uncut are identified to generate a clean-up tool-path for smaller sized tools. The tool-path planning is demonstrated using a part having obstacles within the machining region. The simulated machining is presented in this work. This work extends the accessibility analysis by retaining the topology information and using it to recognize a larger domain of features including intersecting features, filling a void in the literature regarding a method that could recognize complex intersecting features during an automated mold design process. Using this information, a larger variety of new mold intersecting features are classified and recognized in this approach. The second major contribution of the work was to demonstrate that the downstream operations can also benefit from algorithmic decision making. This is shown by automatically generating roughing and clean-up tool-paths, while reducing the machining time by machining only those areas that have uncut material. The algorithm can handle cavities with obstacles in them. The methodology has been tested on a number of parts

Usinage de formes gauches : génération de trajectoires outils à hauteur de crête constante

National audienceWe present in this communication a method to generate constant scallop height tool paths in 3-axis milling with ball endmill. This machining strategy is interesting because it minimises the number of tool paths for a given geometrical specification of form deviation and surface roughness. Our approach is based on the concept of the machining surface which provides a surface representation of the tool paths and an exact model of the scallop generated by the tool path. This approach is confronted with the methods previously developed in the literature in term of precision and more particularly on the processing of curvature discontinuities. Then the constant scallop height tool path planning is evaluated on surfaces of great curvature variations.Nous présentons une méthode de génération de trajectoires à hauteur de crête constante en fraisage à trois axes avec outil hémisphérique. Cette stratégie d'usinage est intéressante dans la mesure où elle minimise le nombre de passes pour des spécification géométriques de défaut de forme et d'état de surface données. Notre approche s'appuie sur le concept de la surface d'usinage qui procure une représentation surfacique des trajets de l'outil et permet une modélisation exacte de la crête laissée par l'usinage. Cette approche est comparée aux méthodes usuelles développées dans la littérature selon des critères de précision et de capacité à traiter les discontinuités en courbure des surfaces. Le problème de la planification des trajectoires iso-crêtes sur une surface présentant d'importantes évolutions de courbure est abordé par la suite

Surface Partitioning for 3+2-axis Machining

Despite the inbuilt advantages offered by 5-axis machining, the manufacturing industry has not widely adopted this technology due to the high cost of machines and insufficient support from CAD/CAM systems. Companies are used to 3-axis machining and the operators are in many cases not yet ready for 5-axis machining in terms of training and programming. An effective solution for this 5 axis problem is a graduated migration through the use of 3+2-axis machining. The objective of this research is to develop and implement a machining technique that uses the simplicity of 3-axis tool positioning and the flexibility of 5-axis tool orientation, to machine complex surfaces. This technique, 3+2-axis machining, divides a surface into patches and then machines each patch using a fixed tool orientation. The tool orientation and section boundaries are determined to minimize the overall machining time. For each section the tool orientation is different but remains constant while machining this section. The number of patches selected for machining has a direct impact on the machining time. If the number of patches is small, the shape of the tool may vary greatly from that of the surface, which can result in smaller side-step distances. In contrast, a large number of patches leads to a better match between the tool and the workpiece, but it also leads to many re-orientations of the part as the tool moves between patches. Also, if the number of patches is large, the size of the patches will be reduced which will result in shorter tool passes that limit the tools ability to achieve the commanded feed rate. The optimum number of patches is a compromise between increasing the side step associated with large patches and the increase in time due to re-orientation of part and tool movement between patches. To find the optimal partition, a series of simulation tests are conducted to find the partition that would lead to the smallest machining time. This work presents the application of well known methods from Pattern Recognition and newly developed methods by the current author that were adapted for surface machining and boundary identification. This work also presents the methodology required to generate tool paths for 3+2-axis machining, which includes an explanation of the procedures required to determine an appropriate tool orientation, feed direction, tool path trajectory and tool parameters for patch-by-patch machining. These parameters are determined independently for each patch and aim at reducing the time required to machine a surface while maintaining the surface specifications. This work presents the surface partitioning scheme and the method of selecting optimum number of partitions along with actual machining experiments. Machining tests on four different surfaces were conducted to demonstrate the efficiency of the proposed technique. The results show that 3+2-axis machine reduced machining times over 3-axis ball nose machining and 5-axis machining using the “Sturz” method. Also, since the tool axis remains fixed during cutting, the tool offers constant feed rates and a better surface finish compared to simultaneous 5-axis