Examples of emulation of die

making and machining experts

Emulation of die making and machining
experts: from technical table
Machining cost calculation
• ABC methodology (Hughes, 2005)
Machining hour calculation for milling
operation (e.g.)
• Toolpath distance m n
Lr 2 = ∑ t i (∑ (r j + 2πjr j ))
i =1 j =1

vc
nr = (Heinzler et al., 1997)
• Spindle RPM πd
f = fz z (Heinzler et al., 1997)
• Tool feed distance
v f = nr f (Heinzler et al., 1997)

• Tool feeding speed

 Lr Lf  1
th =  + ×
v  60
• Machining hour  frough v ffin 
 Emulate wirecut process
• Circular
D
CL = + πD
2

W
• Rectangular
C L = + 2 L + 2W − 4 R + 2πR
2

• CCutting time
Ct = L

vf v f = feeding speed (mm/min)

The way forward /conclusion
• Phase One still in progress
• Automated data abstraction direct from
CAD
• More industry partners for the database
– Calculation algorithms
– Company policy (e.g. profit margin)
• Other machine databases
– Milling
– Turning
– Diesink, etc.
Main flowchart
A Enquiries: mould or die?

B Gets file

C Converts file to SWorks / Inventor

D Designs mould K Designs die

E Identifies plate machine profile E Identifies plate machine profile

F Selects machine F Selects machine

G Machines profiles Phase One G Machines profiles

eCAPP
H Calculates cost
H Calculates cost

J Displays output
J Displays output