Effect of progressive tool wear on the functional performance of micro milling process of injection molding tool

Ali Davoudinejad, Dongya Li, Yang Zhang, Guido Tosello
2020 Procedia CIRP  
G. (2020). Effect of progressive tool wear on the functional performance of micro milling process of injection molding tool. Procedia CIRP, 87, 159-163. Abstract In today's business environment, the trend towards more product variety and customization is unbroken. Due to this development, the need of agile and reconfigurable production systems emerged to cope with various products and product families. To design and optimize production systems as well as to choose the optimal product matches,
more » ... product matches, product analysis methods are needed. Indeed, most of the known methods aim to analyze a product or one product family on the physical level. Different product families, however, may differ largely in terms of the number and nature of components. This fact impedes an efficient comparison and choice of appropriate product family combinations for the production system. A new methodology is proposed to analyze existing products in view of their functional and physical architecture. The aim is to cluster these products in new assembly oriented product families for the optimization of existing assembly lines and the creation of future reconfigurable assembly systems. Based on Datum Flow Chain, the physical structure of the products is analyzed. Functional subassemblies are identified, and a functional analysis is performed. Moreover, a hybrid functional and physical architecture graph (HyFPAG) is the output which depicts the similarity between product families by providing design support to both, production system planners and product designers. An illustrative example of a nail-clipper is used to explain the proposed methodology. An industrial case study on two product families of steering columns of thyssenkrupp Presta France is then carried out to give a first industrial evaluation of the proposed approach. Abstract In micro milling process, tool wear is one of the significant research area and tool behavior during machining is rather unpredictable. As tool wear progress, the cutting edge geometry change and leading to lower performance and failure of the machined surface integrit y. This work investigate the influence of the progressive tool wear during micro end milling of a functional surface (micro ridges) on the injection molding tool with H13 tool steel material. In order to monitor the tool wear progress, five different TiAlN coated carbides micro end mills with 500 µm diameter were used to carry out the experiments in different cutting distances 64 cm to 320 cm. The chip formation, burr formation and surface quality in different tool wear conditions were evaluated. The burr form and size were affected by cutting edge wear and dissimilar results obtained at the end of cut. Moreover, the analysis of chip geometry in microscopic scale allows evaluating the chip morphology and cutting mechanisms in different tool wear conditions. The machined slots by the profile analysis and the surface quality of parts decreased as the tool wear growth. This work contribute to improved knowledge of cutting mechanisms with worn tools causing dissimilar material removal and surface integrity during machining process. Abstract In micro milling process, tool wear is one of the significant research area and tool behavior during machining is rather unpredictable. As tool wear progress, the cutting edge geometry change and leading to lower performance and failure of the machined surface integrit y. This work investigate the influence of the progressive tool wear during micro end milling of a functional surface (micro ridges) on the injection molding tool with H13 tool steel material. In order to monitor the tool wear progress, five different TiAlN coated carbides micro end mills with 500 µm diameter were used to carry out the experiments in different cutting distances 64 cm to 320 cm. The chip formation, burr formation and surface quality in different tool wear conditions were evaluated. The burr form and size were affected by cutting edge wear and dissimilar results obtained at the end of cut. Moreover, the analysis of chip geometry in microscopic scale allows evaluating the chip morphology and cutting mechanisms in different tool wear conditions. The machined slots by the profile analysis and the surface quality of parts decreased as the tool wear growth. This work contribute to improved knowledge of cutting mechanisms with worn tools causing dissimilar material removal and surface integrity during machining process.
doi:10.1016/j.procir.2020.02.031 fatcat:zw3mjt3x35f7pbzr75zgirebk4