Cutting Strategies for Casting Die Manufacturing on CNC Milling Machine

Abstract

Manufacturing of dies has been presenting greater requirements of geometrical accuracy, dimensional precision and surface quality as well as decrease in costs and manufacturing times. Although proper cutting parameter values are utilized to obtain high geometrical accuracy and surface quality, there may exist geometrical discrepancy between the designed and the manufactured surface profile of the die cavities. In milling process; cutting speed, step over and feed are the main cutting parameters and these parameters affect geometrical accuracy and surface quality of the casting die cavities. In this paper, effects of the cutting parameters on geometrical error have been examined on a representative die cavity profile. To remove undesired volume in the die cavities, available cutting strategies are investigated. Finish option for roughing and finish option for finishing are optimized to reduce the Machining time of the cutting process thereby decreasing the cost of cutting process. The cutting parameters considered are Cut Feed, Step Depth, Spindle Speed for both roughing and finishing, scan type for roughing and lace type for finishing.3D model and manufacturing process is done in parametric modeling software Pro/Engineer wildfire5.0.