No abstract

The article deals with comparison and evaluation of the milling strategies that are available in CAM systems and are used to produce components with freeform surfaces. For the purpose of the experiment, sample with freeform features was designed to employ different milling strategies when 3 axis machining. Evaluation of the milling strategies was carried out by surface roughness measurement, comparison of the actual machining time with a simulation time as well as visual control of the sample surface with a surface obtained in simulation. Acquired research results can be utilized within production process of tools with sculptured surfaces, such as tools for metal sheet forming, dies, molds for plastics and many others.

The current mechanical engineering is inconceivable without the implementation of CAx systems in design and manufacturing process of individual components. The automotive industry is a clear evidence of how CAx systems affect the innovation cycle of its product -a car. The innovation cycle in automotive was reduced from 8-12 years to the current 4-6 years. Even in this short interval automakers make some small design modifications called a facelift. Development in the automotive industry, therefore, is closely related to news and functionality CAx systems. CAD systems at the turn of the millennium are characterized as parametric graphic systems with a history tree of product creation. Parametric design implemented into CAD systems makes the model variable and open to rapid change management. The history tree in turn enables rapid editing and modification of forming or editing functions.

The paper deals with selection and evaluation of milling strategies, available in CAM systems and applicable when complicated shape parts are produced, such as forming dies. A method to obtain samples is proposed and this stems from real forming die surface machined by proper strategies. The strategy applicability for the whole part -forming die -is reviewed by the particular specimen evaluation. The presented methodology has been verified by machining model die and comparing it to the production procedure proposed in other CAM systems.

The paper deals with the effects of CAM data needed to produce desired quality of shaped surfaces in forming dies making. In general, the input CAM data have strong influence to the final surface quality. The shaped surfaces 3D milling has been modeled as end ball milling of the surfaces with defined inclination. The end ball milling is the most common way to finish shaped surfaces. Directions of the milling tools motion and applied cutting conditions have been used to simulate data when setting milling strategies. The resultant machined surface quality has been identified in terms of the surface roughness. The paper introduces recommendations applicable to the programming of the different types of milling strategy when producing form surfaces.