Tool Path Planning For Die&Mold Of Auto Panel With High Efficiency Milling

With the improvement of people’s aesthetic standards and requirements for higher vehicle performance, Automotive panel die high-quality processing has become an issue of researchers and engineers increasingly concerned.In this dissertation, Automotive panel front cover die was taken for example,based on the research of planning tool position in the mold surface home and abroad, tool interference, processing tools and so on, With the aid of PowerMILL platform,The goal that high quality processing of automotive panel die was achieved through zoning principle on the mold surface, multi-point machining basic theory, as well as designing new structural tool. The following are the main contents of this dissertation:1. A cutter path subregional planning idea on the mold was put forward which is based on the geometric characteristics of the surface. Firstly established a mathematical model of the mold surface, then discreted the mold surface spatially, and then calculated the geometric parameters(Mainly gaussian curvature, mean curvature, the maximum and minimum principal curvatures) around the discrete points.Finally accurate the boundary lines was abstracted according to criteria of classifying the surface fragments and Z-map method.2. Studyed the basic multi-point theory osculatory processing algorithms based on small curvature of the convex surface mold. And analyzed the existing multi-point machining interference to avoid the problem of the low efficiency on calculateing and the difficulty to avoid local interference, Established a general mathematical model and gave the optimization function and constraints through the comparison of the analysis on algorithm principle, constraints and computing speed. And calculated the knife-bit error distribution and processed bandwidth as well.3. Designed a new rounded end mill based on the same scallop height for maching the mold. Established the mathematical model on the relationship about level spacing and residual cutting height, A theoretical analysis was arranged between the new rounded end mill and original rounding end mill by controling the variable parameter. Analyzed its beneficial processing effects, and the limitations on the application of this new rounded end mill as well.4. Fused the theoretical study of this dissertation and new rounded end mill design together based on typical automotive panel die simulation and experiment on CNC machining. Verifyed the effect of new rounded end milling cutter on roughing; Divided the mold surface by the type of surface features before finishing, Used multi-point machining and machining strategy guides on the surfaces that have already divided, Verified algorithm in this dissertation and provided support and basis on high quality car cover mold processing.