NDLI: Improving the high-speed finishing of forming tools for advanced high-strength steels (AHSS)

Content Provider	Springer Nature Link
Author	López de Lacalle, L.N. Lamikiz, A. Muñoa, J. Salgado, M.A. Sánchez, J.A.
Copyright Year	2005
Abstract	Forming tools manufacturers have extensively incorporated high-speed milling technology for the finishing of large punch or die tools. The main objective is to achieve a good surface quality directly form machining, without any additional, tedious, manual work. Currently, new advanced high-strength steels (AHSS) are being used for car body parts. In this case, there are two special changes related to the forming tools: a higher proportion of harder surfaces on the working area, and long try-out iterations, due to their great springback. Tempered surfaces and insert blocks harder than 60 HRC are needed to withstand the forming charges with a good working life expectancy. From this, two problems arise with regards to high-speed finishing: first, the deflection of the tool due to the cutting forces, which can produce unacceptable dimensional errors; and second, in the same finishing operation, zones with sharp changes in hardness must be machined with the same CNC program and cutting tool.The key to solving both problems will be the use of newly developed utilities in the preparation stage, and the elaboration of CNC programs using CAM software. In the first case, the deflection of tool is dealt with by a milling model which obtains the values of cutting forces. This model characterises the couple tool/material with six coefficients, which are previously obtained for ball-end milling tools and base die materials. Inputs provided by the CAM user include feed per tooth, and radial and axial depths of cut. The problem of surfaces with areas of different hardness and poorly defined boundaries is solved with a special postprocessor coded in C language. Once the CAM user has defined (on the CAD model) the theoretical boundaries of the tempered areas, the insert blocks or the deposition material areas, this utility includes changes of the programmed feed function in the CNC program.In this paper, these approaches are applied to medium size workpieces with the same features of the actual punch and die for AHSS forming. Results are provided to die manufacturers for application in real forming tools. This technological model of the milling process estimates values of cutting forces and offers manufacturers a reduction of production and lead times.
Starting Page	49
Ending Page	63
Page Count	15
File Format	PDF
ISSN	02683768
Journal	The International Journal of Advanced Manufacturing Technology
Volume Number	29
Issue Number	1-2
e-ISSN	14333015
Language	English
Publisher	Springer-Verlag
Publisher Date	2005-09-28
Publisher Place	Berlin, Heidelberg
Access Restriction	One Nation One Subscription (ONOS)
Subject Keyword	High speed milling Dies Moulds Cutting forces Computer-Aided Engineering (CAD, CAE) and Design Mechanical Engineering Production/Logistics Industrial and Production Engineering
Content Type	Text
Resource Type	Article
Subject	Industrial and Manufacturing Engineering Control and Systems Engineering Mechanical Engineering Computer Science Applications Software

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