Study of plunge milling technology with the application of mold machining of camera shell

• Main Authors: Bo-Wen Chang, 張博文
• Other Authors: Jinn-Jong Sheu
• Format: Others
• Language: zh-TW
• Published: 2009
• Online Access: http://ndltd.ncl.edu.tw/handle/42988207423720485886

碩士 === 國立高雄應用科技大學 === 模具工程系 === 97 === During the milling of a female mold cavity, the traditional Z-plane roughing method has to increase the length of cutter and reduce the feed rate to avoid tool breaking. The cutting feed of plunge roughing is in the axial direction of tool, the cutting force is independent with the cutting depth and the plunging feed rate can be kept constant. As a result, the material removal efficiency of plunge roughing is better than the traditional Z-plane toughing. This research aims at the study of plunge roughing technology and the cutting process characteristics. The cutting efficiency and cutting forces are studied with different plunge roughing tool path designs. Female mold cavities of a camera shell are designed to study the effects of cutting depth and island features on the efficiency. In this research, plunge roughing tool path designs of different software (Pro/E and Power Mill) had been evaluated based on the rectangular and the triangular path calculation criteria. The cutting results of the traditional Z-plane and the plunge roughing were compared. Design of experiments (DOE) method was adopted to find the better tool path designs and cutting conditions of both roughing methods. DOE method was also adopted to find the smaller cutting force of plunge roughing experiments measured with 3-axis dynamometer. Finish cuttings were also taken into consideration to obtain more complete efficiency comparison. Aluminum alloy 6061-T6 was adopted in all of the cutting experiments to save time and avoid tool wearing. The cutting experiments had shown the cutting force of plunge roughing is proportional to the plunge feed rate. The better material removal rate was obtained under the condition of plunge feed rate 610 mm/min, 4200 rpm, step distance 16mm, and spiral tool path design. The cutting simulations also showed the cutting efficiency of plunge roughing is increased with increase of cutting depth with respect to the Z-plane roughing. The relocate tool path proposed in this research can also improve the cutting efficiency.