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+M. R. Alam, +K. S. Lee, +M. Rahman, +Y. F. Zhang, *Y. D. Li and *K. S. Sankaran
+Department of Mechanical Engineering, National University of Singapore
Abstract
As EDM is a rather slow process, mould makers are forced to look for alternative processes in order to stay competitive. With the emerging technology, high speed machining (HSM) is a much faster process compared to EDM. Recently, HSM is being considered as a replacement for EDM in the manufacturing of moulds. However, HSM may not be appropriate for
machining all types of moulds. In this study, an algorithm has been proposed to select the most appropriate process whether HSM or EDM, or a combination of both for the manufacture of a particular mould. Several case studies have
been conducted and the economics of different processes have been analysed to justify the suitability of the algorithm. From the case studies, it
is concluded that, for the machining of a particular mould, HSM is preferred if found to be suitable. But the decision for the selection may depend on the setup of the organization and constraints.
Keywords
1. INTRODUCTION
Process planning is an important task in a manufacturing organisation. Among the process planning activities, selection of appropriate processes to manufacture a part is the most important one. Timing is critical for any mould making company wishing to have the leading edge in todays world market. Many manufacturing companies are willing to pay high premium for a shorter delivery lead-time of a mould [1]. Machining of injection mould needs considerable amount of time and money. At the same time it needs high accuracy. The competition is fierce in this area too. Considering accuracy, surface finish and high rate of production for the competition, a lot of new technologies are emerging in recent years. Mould manufacturing companies are beginning to adopt advanced technologies and machinery to reduce the leadtime, cost and improve quality. Among the advanced technologies, high speed machining (HSM) is the most emerging one. It offers good surface finish, shortens the processing time and reduces cost [2]. Electrical Discharge
Machining (EDM) is an essential process in mould manufacturing. Some mould cavities cannot be manufactured without this process [3]. But EDM is a very slow process compared to HSM. As a result, delivery lead-time of mould cannot be reduced significantly due to the EDM process. So mould makers are forced to find alternative processes for EDM. However, HSM is the faster process compared to EDM, but it may not be appropriate for all types of moulds. A few studies have been conducted to compare the economics between HSM and EDM. Aspinwall and Dewes [4] presented an analysis that compared the manufacture of a forging die by EDM with HSM. But the times and costs were based on the experience of the authors and not a real life example. Schumacher and Schulz [5] presented a comparison of EDM and HSM on the basis of typical applications, key features, process monitoring, equipment, work planning and staff knowledge of the process. But this comparison gives the general idea about two different processes. However, no algorithm has been proposed so far to select the most suitable method. In this study, an algorithm has been proposed to select the most appropriate processes for the manufacture of a particular mould and the economics of the processes have been analysed to justify the suitability of the algorithm.
or equal to 3 and hardness is between 32 HRC and 55 HRC, generally HSM is a preferable choice and if L/D is greater than 3 and hardness is greater than 55 HRC, EDM is used. Figure 1 is drawn for low speed machining (LSM), HSM and EDM based on thumb rules applied for selection of appropriate machining processes.
The high L/D ratio cutter increases run-out and a cutter with 0.01 mm run-out extends tool life up to 300% than one with 0.04 mm run-out [7]. On the other hand, run-out affects surface finish and contouring of the corners of the mould cavity.
moulds by using different processes. Total processing time is calculated from the total set-up time, machining time, programming time and design time. All data are obtained by conducting different experiments. On the other hand, total processing cost is calculated by the addition of material cost, tool cost, machining cost, programming cost and design cost. Machining cost, design
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cost and programming cost are calculated from the multiplication of corresponding time and hourly rate of a particular company. In the following case study, economics for different processes are analysed.
4. CASE STUDY
Several case studies are tested with the algorithm. In this article, a cavity for an electronic component shown in Figure 2 is presented to verify the algorithm and compare the economics between HSM, EDM, and a combination of both. According to algorithm, HSM is appropriate for the machining of this cavity. Three different experiments are conducted to compare the economics and surface finishes. The first experiment is the machining of the cavity by HSM; the second experiment is the machining of cavity by EDM and third experiment is the machining using combination of both HSM and EDM.
Figure 2: A cavity of an electronic component The maximum length, width and height of the cavity shown in Fig. 2 are 117.77 mm, 28.30 mm and 5 mm respectively. There are two bosses having diameters 4.72 mm and 3.25 mm respectively in the cavity. Heights of the bosses are 3 mm. The blend radii in top and bottom of the boss are 1.55 mm and 0.75 mm respectively. The taper angle is 2 degrees. The blend radius all along the bottom edge is 2 mm. The material used is ASAAB Stavx (AISI 420 MOD) and the hardness of the material is 51 HRC. Three ball nose end mill carbide cutters having diameter 6, 3 and 1.5 mm, coated with TiALN are used for the machining of cavity and copper electrodes used for the EDM experiments. The model of the electrode is shown in Figure 3 and comparative analysis of different experiments is shown in Table 2.
6. REFERENCES
1. 2. 3. 4 Alam M. R., Lee K. S., Rahman M., Zhang Y. F., Automated process planning for the manufacture of sliders. Computers in Industry 2000; 43: 249-262. Ikeda, T. et al., Ultra high speed milling of die steel with ball-nose end mill. Proceedings of International Conference on Die and Mould Technology (ICDMT), Singapore, 1992; 48-46. Tanaka K. Precision die and mould manufacturing-a case study. Die and Mould Manufacturing International, April 1991; 47-50. Schumacher B., Sculz, H., EDM competing HSC- tool manufacturing/hardened steel, CIRP-2000-WG E/C-2, January 2000; Paris, France. Aspinwall, D. K., Dewes R. C., EPSRC case for support - ultra high speed machining of hardened ferrous alloys, school of manufacturing and mechanical engineering, University of Birmingham, 1994. Technical guide- SECO Tools AB, Sweden. Tooling systems- catalogue, MST Corporation, Japan 2000.
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