Details
| Original language | English |
|---|---|
| Pages (from-to) | 45-50 |
| Number of pages | 6 |
| Journal | Procedia Manufacturing |
| Volume | 40 |
| Publication status | Published - 2019 |
| Event | 19th Machining Innovations Conference for Aerospace Industry 2019 (MIC 2019) - Hannover, Germany Duration: 27 Nov 2019 → 28 Nov 2019 Conference number: 19 |
Abstract
The process of repairing damaged tool moulds is conducted manually in the industry. This results in long process times as well as a high dependence of the repair result on the experience of the worker. After a visual inspection, the detected damages are removed by metal cutting and the missing material is filled by a build-up welding process. Afterwards, the target geometry is restored via machining re-contouring process. Because of the individual tool mould surface and welded seam, each repair case requires an individual machining strategy as well as toolpaths and process control parameters to ensure high surface quality and shape accuracy. This paper introduces an innovative design for re-contouring of repair-welded tool moulds, which takes into consideration the individual mould surface, repair welding and material properties. For that purpose, the actual geometry of the tool mould is measured directly in the CNC machine using an optical profile line sensor. Based on the measurement, the re-contouring process is planned automatically by means of a computer aided manufacturing (CAM) software. A material removal simulation with cutting force prognosis is carried out to adapt the process parameters individually with regard to repair time and surface quality. To set up the force and surface simulation model with high model quality, re-contouring experiments are carried out on welded seams made of 1.2343 (AISI H11) as well as on Toolox 44 and 1.2343 workpieces for comparison.
Keywords
- Automation, In-process measurement, Material removal, Mold (Mould), Planning, Sensor, Simulation
ASJC Scopus subject areas
- Computer Science(all)
- Artificial Intelligence
- Engineering(all)
- Industrial and Manufacturing Engineering
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In: Procedia Manufacturing, Vol. 40, 2019, p. 45-50.
Research output: Contribution to journal › Conference article › Research › peer review
}
TY - JOUR
T1 - Automatic re-contouring of repair-welded tool moulds
AU - Denkena, Berend
AU - Dittrich, Marc-andre
AU - Heide, Klaas Maximilian
N1 - Conference code: 19
PY - 2019
Y1 - 2019
N2 - The process of repairing damaged tool moulds is conducted manually in the industry. This results in long process times as well as a high dependence of the repair result on the experience of the worker. After a visual inspection, the detected damages are removed by metal cutting and the missing material is filled by a build-up welding process. Afterwards, the target geometry is restored via machining re-contouring process. Because of the individual tool mould surface and welded seam, each repair case requires an individual machining strategy as well as toolpaths and process control parameters to ensure high surface quality and shape accuracy. This paper introduces an innovative design for re-contouring of repair-welded tool moulds, which takes into consideration the individual mould surface, repair welding and material properties. For that purpose, the actual geometry of the tool mould is measured directly in the CNC machine using an optical profile line sensor. Based on the measurement, the re-contouring process is planned automatically by means of a computer aided manufacturing (CAM) software. A material removal simulation with cutting force prognosis is carried out to adapt the process parameters individually with regard to repair time and surface quality. To set up the force and surface simulation model with high model quality, re-contouring experiments are carried out on welded seams made of 1.2343 (AISI H11) as well as on Toolox 44 and 1.2343 workpieces for comparison.
AB - The process of repairing damaged tool moulds is conducted manually in the industry. This results in long process times as well as a high dependence of the repair result on the experience of the worker. After a visual inspection, the detected damages are removed by metal cutting and the missing material is filled by a build-up welding process. Afterwards, the target geometry is restored via machining re-contouring process. Because of the individual tool mould surface and welded seam, each repair case requires an individual machining strategy as well as toolpaths and process control parameters to ensure high surface quality and shape accuracy. This paper introduces an innovative design for re-contouring of repair-welded tool moulds, which takes into consideration the individual mould surface, repair welding and material properties. For that purpose, the actual geometry of the tool mould is measured directly in the CNC machine using an optical profile line sensor. Based on the measurement, the re-contouring process is planned automatically by means of a computer aided manufacturing (CAM) software. A material removal simulation with cutting force prognosis is carried out to adapt the process parameters individually with regard to repair time and surface quality. To set up the force and surface simulation model with high model quality, re-contouring experiments are carried out on welded seams made of 1.2343 (AISI H11) as well as on Toolox 44 and 1.2343 workpieces for comparison.
KW - Automation
KW - In-process measurement
KW - Material removal
KW - Mold (Mould)
KW - Planning
KW - Sensor
KW - Simulation
UR - http://www.scopus.com/inward/record.url?scp=85084403433&partnerID=8YFLogxK
U2 - 10.1016/j.promfg.2020.02.009
DO - 10.1016/j.promfg.2020.02.009
M3 - Conference article
VL - 40
SP - 45
EP - 50
JO - Procedia Manufacturing
JF - Procedia Manufacturing
SN - 2351-9789
T2 - 19th Machining Innovations Conference for Aerospace Industry 2019 (MIC 2019)
Y2 - 27 November 2019 through 28 November 2019
ER -