5 축 CNC 기계에서 다이최적가공을 위한 CAD-CAPP-CAM 시스템 통합 : Integration of CAD-CAPP-CAM System for Optimal Machining Mold Dies with 5-axis CNC Machine

다국어 초록 (Multilingual Abstract)

Feature-based methods have emerged in response to vital industry needs in design and manufacturing, particularly the need to reduce product development times. Product design and production engineering functions must become closely integrated with manufacturing, and all bottle-necks in the flow of product and engineering information from these functions to the manufacturing function must be eliminated. The close integration between design (CAD), planning (CAPP), and manufacturing (CAM) functions requires that sufficiently complete and accurate information of all aspects of products, production processes, and operations is available. Hence, future design and planning systems will be closely aligned with manufacturing technology, and future manufacturing systems will need more complete and accurate product information than what is currently possible. Ideally, this integration should lead to concurrent life-cycle engineering, where all design, manufacturing, maintenance, and eventual dismantling and reuse issued of the product can considered simultaneously during its design.
This thesis proposes the integration of CAD/CAPP/CAM for optimal machining of mold/dies with five-axis CNC machine. The first, complete integration of process chain:” Design-Planning-Manufacturing” is performed to eliminate bottle-necks of design, planning and manufacturing process. This integration responds complete and accurate product information in process chain from the design stage to the manufacturing stage. Specially, in the worldwide market for the injection die/mold, many large companies have attempted to introduce flexible manufacturing systems as their strategy to adapt to the ever-changing competitive market requirements.
The second, the design of die/mold requests many complex surfaces and the quality of manufactured surface. To ensure the quality of machining surface, to reduce the machining costs and increase the machining effectiveness, it is very important to select the machining parameters in CNC machining. The quality of products manufactured by injection molding process is highly influenced by that of mold surfaces obtained from selecting optimal machining parameters such as cutting speed, feedrate, radial and axial depth of cut, machining tolerance, and surface roughness. The optimization of these parameters is the key component in the planning of machining processes.
The finally, all of modules are integrated in the unique environment based on CATIA V5 R16. This integration is developed in our view following three directions:
- Using automatic objects of CATIA V5 to integrate the process chain: ”Design-Planning-Manufacturing” based on feature technology and STEP standard.
- Developing more function corresponding with the process chain: ”Design-Planning-Manufacturing”. The catalog technology is used in CAD/CAPP and CAPP/CAM stage to shorten coincided step in planning process.
- Optimizing the cutting parameters for machining mold/die with five-axis CNC machine. The response surface methodology is used for achievement of optimal machining.

목차 (Table of Contents)

• Chapter 1 Introduction = 1
• 1. Background = 1
• 1.1 Feature-based CAD/CAM = 2
• 1.2 Interactive and automatic feature recognition = 5
• 1.3 Feature Recognition = 9
• 1.4 Comparison of feature recognition techniques = 11
• 1.5 STEP Standard = 13
• 2. Motivation = 19
• 3. Methodology = 23
• Chapter 2 Integration of Process Chain = 25
• 1. Overview = 25
• 2. Integration Conditions and Environment = 28
• 2.1 Integration Conditions = 28
• 2.2 Integration Environment = 31
• 2.3 Standards of Integration = 33
• 3. Integration of process chain = 35
• 3.1 Automatic Object of CATIA = 35
• 3.2 Integration interface = 36
• 4. Comparison of Approaches = 41
• Chapter 3 Integration of CAD/CAPP and CAPP/CAM = 43
• 1. Overview = 43
• 2. Integration of CAD/CAPP = 46
• 2.1 CAD information = 46
• 2.2 Feature Recognition = 47
• 2.3 Feature conversion = 49
• 3. CAPP/CAM integration = 50
• 3.1 The tasks of CAPP/CAD integration = 50
• 3.2 Architecture of integration CAPP/CAM = 53
• 3.3 Converter = 55
• 4. Automatic information interface and catalog technology = 59
• Chapter 4 Optimizing cutting parameters = 61
• 1. Overview = 61
• 2. Response Surface Methodology = 64
• 3. Experiment Preparation = 67
• 4. Experimental Design = 69
• 5. Analysis of Result and Discussion = 72
• Chapter 5 CONCLUSION = 77
• 1. Summary = 77
• 2. Contributes = 78
• 3. Future Work = 79
• Bibliography = 80