Politehnica University of Bucharest

Faculty of Engineering and Management of Technological Systems

Computer Aided Manufacturing

(add image?)

Student: Lecea Mihai-Vladimir

Professor: Prof. Dorel Ananei
 Table of content
1 Model 3D of the part – Short presentation , material characteristics
2 Technological Analyze form CAM point of view
2.1 Surface identification. Color code for surface roughness
2.2 Analyze of the geometrical feature :
2.3 Surface integrity ,Surface angle ,Wall thickness
2.4 Establish the clamping of the work piece/stock
3 Work piece definition, for each part position
4 Establish of part positioning
5 Establish the cutting tool list
5.1 Geometrical characteristic of the tool, tool body.
5.2 Cutting parameters for each tool for each cutting phase (roughing, rerough
etc) for the part material (formula, values)
5.3 Holder definition.
6 Machining phase for each part position (detail and justification of parameters)
6.1 Rough/re-rough
6.2 Finishing
6.3 Re-machine/clean up, pencil
6.4 Drilling /Taping
7 Post-processing , NC file analysis
8 Reports
9 Machining time analysis
10 Part comparing (CAD-Simulation-3D Scan)
11 Proposal for optimum CAM technology
12 Machining presentation Movies, PowerPoint
1. Model 3D of the part – Short presentation, material characteristics

Computer-Aided Manufacturing(C.A.M) refers to the use of numerical control (NC) computer

software applications to create detailed instructions (G-code). These applications, also known
as dedicated software, drive computer numerical control (CNC) machine tools for the
manufacturing the desired parts.

A broader definition of C.A.M can include the use of a dedicated software (NX CAM, CimatronE
or hyperMill for example) to define a manufacturing plan for tooling design, computer-aided
design (CAD) model preparation, NC programming, coordinate measuring machine (CMM)
inspection programming, machine tool simulation, or post-processing.

The working part analyzed for this project is a V-bending die. Its usage is for V-bending ,the
most common method used with press brake bending. During the bending process, the die is
mounted on the work bench and a punch applies a distributed bending force on the blank.
In Figure 1 it is presented a 3D Image of the part in CimantronE in CAD mode and a
demonstration of V-vending.

Figure 1

The material selected to manufacture this work piece is 42CrMo4 (High grade steel). Properties of the
material have been extracted from the MATBASE website in Table 1:

Name of material 42CrMo4 (High grade steel)

Density 7830 kg./m3
Tensile strength 1000 MPa (Min.) ; 1200 MPa (Max.)
Yield strength 550 MPa (Min.) ; 800 MPa (Max.)
Young`s Modulus 2 x 104 MPa

2. Technological analysis from CAM point of view

The die is measured and analyzed in the CAM module of CimatronE. All the important data of the die are
collected and displayed in the following sub-chapters.

2.1 Surface identification. Color code for surface roughness

The die has a 51 faces, a total area of the faces of 41223.784 mm2 the mass of 2680.088 grams. And the
UCS of the part is positioned on the reference system at the coordinate of (X=75 ; Y=30 ; Z=-15).
All surfaces have been identified and detailed in the Table 1. Most surfaces of the die are planar
(rectangular or polygon). In Table 2, the surfaces identified as “complex” are irregular polygonal
surfaces. Their “main” dimension refers to a rectangle that by-passes the polygon.

Table 1: Details of the die`s surfaces

Surface Type Dimension Area(mm2) Perimeter Roughness

nr. (mm) (mm) (Ra)
S1 Planar face 20 x 55 1100 150 3,2
S2 Planar face 5 x 55 275 120 3,2
S3 Planar face 10 x 55 550 130 3,2
S4 Planar face Main: 60 x 45 2650 210 6,3
S5 Planar face Main: 150 x 35 5089.436 381.312 6,3
S6 Planar face Main: 15 x 58.434 613.257 135.582 6,3
S7 (x2) Planar face 5 x 58.434 292.171 126.869 3,2
S8 Planar face Main: 15 x 58.434 663.257 135.582 3,2
S9 Planar face 9 x 30 270 78 3,2
S10 Planar face 14 x 30 420 88 3,2
S11 Planar face Main: 60 x 48.051 2049.399 258.168 1,6
S12 Planar face Main: 60 x 48.051 2722.327 216.102 1,6
S13(x2) Planar face 3.819 x 60 229.130 127.638 2
S14(x2) Planar face 2.5 x 60 150 125 2
S15(x2) Planar face Main: 22 x 47.715 964.626 132.301 0,80
S16 Planar face 12.524 x 30 387.517 86.781 0,80
S17 Planar face 30 x 47.715 133.421 155.430 0,80
S18(x4) Cylindrical face R:2.75 h:22 380.133 - 0,80
S19(x2) Planar face Main:1.414 x 30 42.251 62.602 0,80
(1 x 45°)
S20(x2) Planar face Main: 20.309 x 28.986 44.429 0,80
(chamfer) 1.436 (1 x 45°)
S21(x2) Planar face Main: 0.926 x 16 14.510 33.405 0,80
(chamfer) (1 x73°)
S22 Planar face Main: 60 x 50 2234 264.828 6,3
S23(x2) Planar surface 150 x 60 4500 270 6,3
S24 (x4) Cylindrical face R: 5 h: 5 157,080 31.416 6,3
S25 Planar face Main: 150 x 50 636,950 418.740 6,3
The color code for the die is displayed Figure 2. Five colors have been selected to display the roughness
of every surface: white, blue, green, gray and yellow. The color code is displayed in Table … below.

White Yellow Blue Green Gray

0,80 1,6 2 3,2 6,3
2.2 Analysis of geometrical feature
The original block of the die was block of dimension 170 x 70 x 55. This type of stock is called
Box in CimatronE. In Figure 3 it is displayed the initial stock of the die using blue. In our case, it
also displays how much material has to be removed in order to obtain the die.

Next, the die is subjected to draft angle analysis using the Direction Analysis. This function
allows us to see the inclination of every surface from the Z axis. Figure 4 displays the inclination
of every surface using Draft angle Analysis, Slope Analysis (NC). The die has only one undercut
surface colored in red: the bottom surface (S25).

The surfaces colored in purple are perpendicular with the bottom face of the part (90°). The
green surfaces horizontal and the yellow ones have an inclination of 27.81°. Some blue surfaces
can be observed in Figure 4. These blue surfaces are chamfers with an inclination of 45°,
respectively 51.29°. Another chamfer, colored with yellow has an inclination of 17.19°.
 Figure 4

In Figure 5 the die has been subjected to Zebra Shading Analysis. This feature analyzes the smoothness
of a part, and allows users to ensure G2 continuity. Black and white stripes are projected onto the die to
identify the smallest deviation on a set of surfaces.

Figure 5
2.3 Surface integrity, Surface angle, Wall thickness

Surface integrity is the sum of all the elements that describe the conditions existing on or at the surface
of the piece. Changes on the part can be caused by chemical, thermal, electrical or mechanical energy
and affect both the physical and the metallurgical properties of the material.

The altered material zones can be grouped by their principal energy modes as follows in the table
below:

Mechanical Metallurgical Chemical Thermal: Electrical:

Plastic Transformation of Inter-granular Heat affected zone Conductivity
deformations phases attack ( IGA) (HAZ) change

Tears and laps Grain size and Inter-granular Recast or re- Magnetic change
shape corrosion (IGC) deposited material
Hardness
alterations Precipitate size Inter-granular
and distribution oxidation (IGO)

On the die there is no altered material zone. But Figure 6 shows an area of the die with a lap where S19
intersects with S21 and the same area in Zebra Shading analysis. This can be caused by an importing
error of the part due to the STP format.

Figure 6: The import error at the intersection of S19 and S21.

Wall thickness is an important parameter for the design of the part. Thin wall sections cause breakage of
parts during manufacturing or during usage of the part.
Optimal wall thickness is also important for adequate and sufficient strength of parts. The die for the
project has been subjected to Wall Thickness analysis in CimatronE. Figures 7.1 and 7.2 display the die in
Wall Thickness Analysis.

Figure 7.1: The Wall Thickness Analysis (Sphere Analysis) of the die in ISO View.

Figure 7.2: The Wall Thickness Analysis of the bottom surfaces.

2.4 Establish the clamping of the work piece/stock
The clamping of the work piece is an essential step in order to obtain the part with all the desired
requirements.

The manufacturing of the die in CimatronE is performed on a 3-axis tool path. In order to manufacture
de part, there are required procedure on 3-axis and 2.5 axis.

The die has most of the surfaces are planar on the XY plane, on different levels on the Z axis. Figure 7
displays a hold-down clamp suitable for the manufacturing of the die.

Figure 8: Hold-down clamp.

In CimatronE software, the part to be manufactured is required to have one or more tool paths. A tool
path is always determined before the procedures for the part are performed, along with the stock.

For this die, four tool paths are determined, due to the global stock offset of 5 millimeters. It also needs
different UCS origins. These will be determined along the way. For each UCS, there is a specific clamping
of the 42CrMo4 block.

In Figure 9.1 it is displayed the clamping of the die with the technological surfaces upwards on the Z axis.
This is the first clamping for the block. The result from this clamping are the technological surfaces of
the die (S1,S2,S3,S6,S7,S8,S9,S10,S11,S12,S13,S14).

The gap observed in Figure 9.1 is the 5 millimeters gap of the stock where the clamping is directly on the
stock but not on the part.

For the first clamping, the first tool path is defined and UCS19 is the selected user coordinate system for
the set of procedures demanded to obtain the technological surfaces
 Figure 9.1: The first clamping of the die in ISO view. Selected UCS: UCS19

….
3. Work piece definition, for each part position.

Bending of metal sheet is a common and vital process in manufacturing industry. Sheet metal bending is
the plastic deformation of a metal sheet over an axis, changing its geometry. Bending processes differ in
the methods to plastically deform the sheet or plate.

One of the most common types of metal sheet manufacturing processes is V bending. The V-shaped
punch applies a force to the sheet and bends it. This type of process can bend both acute and obtuse
angles and 90° angles. Figure 9 displays an example of V-bending process.

Figure 8: The V-bending process.

The given die for this project is for V-bending. After a detailed analysis of the die in CimatronE, the die is
designed for the manufacturing of metal sheets which require an obtuse angle, 124,374°.

The material of the die is a high grade steel , 42CrMo4. In the process of manufacturing, every material
block has its own cutting regime. The cutting regime is characterized by the cutting speed (m/min), the
spindle speed(rpm), presence of the cooling agent, specific cutting force(N/mm2) and the feed per
revolution(mm/rev).

The parameters of the cutting regime are the following:

 Specific cutting force (kct): 1100 N/mm2;

 Cooling agent: oil emulsion;
 Cutting speed (vc): 25m/min.;
 Spindle speed: 400 r.p.m.;
 Feed per revolution: 0,08 (mm/rot.);
 Feed per tooth: 0,15 mm
4. Establish of part positioning.
The position of dies in a bending machine is on a die holder. The die can be fixed to the die holder
directly by screws or by a clamping block. The V-bending die for this project has a technological fixing
gap (surfaces S15, S16,S17, S18) to allow a clamping block the fixing of the die to the holder. Figure 9
displays the fixing of the die with a clamping block.

Figure 9.1: The clamping block (colored in red) for the die in ISO View.

Figure 9.2: The bolts for the clamping block (colored in black).
 Figure 9.3: The die fixed to the holder (in light-blue).

The parts that are manufactured on the die are metal sheets, with their thickness ranging from (1/16)
inches to 3/4 inches (1.58 mm. to 1,9 mm) being the first and last values of the standard. When the
work, or metal sheet is placed on the die to be bent, it uses two surfaces of the die as a support. Figure
10 displays a metal sheet of 1,9mm thickness that is placed on the die. Surfaces S1, S9 and S10 serve as
a support for the metal sheet.

Figure 10. Position of the plate(colored in purple) on the die.

5. Establish the cutting tools
In the manufacturing plan for a part, there are two important factors which an engineer must take into
account: the cutting regime and the list of cutting tools.

The cutting regime of a material is a set of parameters (cutting speed , spindle speed, presence of the
cooling agent, specific cutting force, feed per revolution) that allow the manufacturer to obtain proper
products with the selected material. The list of tools contains all the necessary tools for the procedures
to obtain the desired part.

The V-bending die given for this project has a defined cutting regime and an established list of tools and
procedures. In Figure 11 are presented the tools required for the manufacturing of the die (the tools are
represented in Cimatron E Cutters and Holders creator). Only general tools are presented. Specific tool
will be presented further.

Figure 11:Tools required for the manufacturing of the die. Taper mill(a), Drill (b), Ball mill (c), End
mill(d), Centering drill(e)
5.1 Geometrical characteristics of the tools

In any manufacturing plan for a product, the tools involved in the manufacturing are divided
into two groups: roughing tools and finishing tools. Roughing tools are for deep cuts and
material removal from the work piece. Finishing tools give a specific roughness on a surface of
the part, depending on the use of surface.

Table 2 displays the data of the tools for the rough milling procedure, including the resulting
surfaces. Table 3 displays the same, but for the rough drilling.

Rough milling tools

Tool name Tool type Characteristics Resulting surfaces
RMT1 End mill Ø: 6 mm. S6, S7, S8, S5
Cut height: 18 mm.
Clear length: 45 mm.
RMT2 End mill Ø: 15 mm. S1, S2, S3, S4, S9, S10,
Cut height: 10 mm. S22, S25.
Clear length: 45 mm.
RMT3 Ball mill Ø: 20 mm. S11, S12
Corner radius: 10.
Cut height: 10 mm.
Clear length: 45 mm.
RMT4 End mill Ø: 5 mm. S13, S14
Cut height: 5 mm.
Clear length: 45 mm.
RMT5 End mill Ø: 20 mm. S15, S16, S17
Cut height: 25 mm.
Clear length: 45 mm.
RMT6 End mill Ø: 5 mm. S15, S16, S17
Cut height: 25mm.
Clear length: 45 mm.
RMT7 End mill Ø: 5 mm. S19, S20, S21
(for chamfers) Taper angle: 45°
Cut height: 25mm.
Clear length: 60 mm.
RMT8(?) End mill Ø: 20 mm. S23, S25, S4
Cut height: 23mm.
Clear length: 60 mm.
RMT9 End mill Ø: 5 mm. S24, S26
Cut height: 10mm.
Clear length: 40 mm.
 Rough drilling tools
Tool name Tool type Characteristics Resulting surfaces
CDT1 Center drill X S18, S24, S26
DT1 Drill Ø: 5,3 mm. S18
Taper angle: 118°
Cut height: 25mm.
Clear length: 45 mm.

5.2 Cutting parameters for each tool for each cutting phase (roughing, rerough etc) for the
part material (formula, values)