Increasing productivity in die machining through process modelling

Die manufacturing is a very critical part of the overall production chain in many industries. Depending on shape and size of a die, machining time can be very time consuming. Furthermore, since usually one die is manufactured, the chance for testing is very limited. Machining processes in die manufacturing can be limited by many factors. Process models can be used in order to select process conditions which will yield the required quality in the shortest possible time. In this study, force, tool deflection and chatter models are developed for different materials and tool geometries used in an automotive die shop. Tool geometries are modelled and frequency response functions (FRFs) are measured for different combinations of machine tools and cutting tools for the chatter stability analyses. Using the developed models, process parameters are modified and their effects on productivity are demonstrated.