University Politehnica of Bucharest

Computer aided manufacturing

-project-

Student: Professor:
Cosmin Badea Florea Dorel Anania
 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 workpiece/stock

3 Workpieces definition, for each part position

4 Establish of part positioning

5 Establish of 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, refought
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/ refough
6.2 Finishing
6.3 Remachine/clean up, pencil
6.4 Drilling /Taping

7 Postprocessing, 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

 Chapter 1
model 3D of the part

Short presentation
https://en.wikipedia.org/wiki/Cimatron

CimatronE is an integrated CAD/CAM solution

for mold, die and tool makers and manufacturers of
discrete parts, providing associativity across the
manufacturing process from quoting, through design
and delivery. The solution's products include mold
design, electrode design, die design, 2.5 to 5-
axis numerical control programming and 5-axis
discrete part production.

The part which will be analyzed can be seen in Figure 1. It is a die and it
used for bending sheet metals. The sheet metal is placed on the top of the
die and a punch is used to press it until the desired shaped is obtained.

Figure 1

Material characteristics:
https://www.matbase.com/material-categories/metals/ferrous-metals/steel/low-alloy/medium-carbon/

The part is made out of medium-carbon steel (C35)

Chemical Composition:
Ferro (Fe) rest, Carbon (C) 0.32-0.39%, Silicon (Si), Sulphur (S) rous (P)

Electrical properties:
Min Value Max Value Unit
Electrochemical potentianl -0.45 -0.45V

Mechanical properties:
Min Value Max Value Unit
Density 7850 7850 kg/m³
Elongation 17 17%
Tensile strength 630 780 Mpa
Yield strength 430 430Mpa
Young’s modulus 205000 205000 Mpa

Thermal properties:

Min Value Max Value Unit

Melting temperature 1500 1500 °C
Specific heat 440 440J/kg.k
Thermal conductivity 46 46W/m.K
Thermal expansion 15 15 e-6/K
 Chapter 2
Technological Analyze form CAM point of view

2.1 Surface identification. Color code for surface roughness

The die has 133 edges and 51 faces as can it be

seen in Figure 2 and an Area of 41003.784 mm²
Figure 3

Figure 2

Figure 3

The die is made out of 4 different types surfaces as follows (Figure 6):
Red- Flat/Plane surface
Green – Inclined Flat surface
Blue - Chamfer
Yellow – Cylindrical

Figure 4
The roughness of the part is as follows (figure 4 & figure 5):
Blue - 6.3
Yellow – 1.6
Green - 3.2

Figure 5 Figure 6

2.2 Analysis of the geometrical feature

Curvature map analysis is useful for determining the necessary tools for processing the part. This way the
tools will be chosen easier and with a better accuracy. In this we have 4 holes which require a cutting tool
with the radius 2.75
2.3 Surface integrity, Surface angle, Wall thickness.

Trough zebra shading show us the continuity, the flow of the part. In this case, there was no
problem found.

There are 5 different angles for this part as it can be observed in the next 2 images:
Green - 0°
Light green- 27.81°
Purple - 90
Light Blue (chamfer) - 45°
Red – 180°
The thickness of the part, is shown in Figure 7. Thickness is a very important aspect of the part.
If the part doesn’t have the optimal thickness it may fail when the punching is done.
Pink - >10mm
Dark blue - ~5mm
Light Blue - ~2mm
Purple - ~10mm
Yellow - ~0.5mm

Figure 7

2.4 Establish the clamping of the workpiece/stock

In order to be processed the blank part needs to be fixed in a jaw vise in two position. In 1st
position the blank part is grabbed in the vise by the lower side and the top is processed. In the 2nd
position the blank is fixed in the vise by the top part and the bottom is processed.
 Blank

1st position
2nd position

Chapter 3
Workpieces definition, for each part position

Bending is the metal working process by which a straight length is transformed into a curved length. It is
very common forming process, for changing sheet and plate into channels, drums and tanks etc. During
the bending operation, the outer surface of the material is in tension and the inside surface is in
compression. The strain in the bent material increases with decreasing the radius of curvature
The die used user is a V-type die; used for V-bending. In v-bending, a wedge-shaped punch forces the
metal sheet or strip into a wedge-shaped die cavity, shown in fig.
The bend angle may be acute 90°, or obtuse. As the punch descends, the contact forces at the die corner
produce a sufficiently large bending moment at the punch corner to cause the necessary deformation. To
maintain the deformation to be plane strain, the side creep of the part during its bending is prevented or
reduced by incorporating a spring loaded knurled pin in the die.
In V-type bending are processed metal sheets. Metal sheet is a metal formed by an industrial process into
thin, flat pieces.

Sheet metals V-type bending

Chapter 4
Establish of the part position

In order to process the workpiece, we shall fix it in a vise in position. In 1st position the milling
of the part will be done and in the 2nd position the drilling.
 1st position

2nd position

Chapter 5
-Establishing of the cutting tool list-

5.1 Geometrical characteristic of the tool, tool body.

During the process 6 different cutting tools were used. For the flat surfaces I used milling 1 ,
milling 2 and finishing and for the drilling cdrill , drill and drill 1

5.2 Cutting parameters for each tool for each cutting phase (roughing, rerough etc) for the
part material (formula, values)
The tools were defined as follows:
 5.3 Holder definition
A holder is a short steel bar having a shank at one end by which it is clamped to a machine and a
clamp at the other end to hold small interchangeable cutting bits.
Tool holders have three main parts: the taper, the flange, and the collet pocket. Driven or "live"
tooling is powered, while static tooling is not.
  The taper is the conically-shaped area of the tool holder that enters the spindle during tool
changing.
 The flange is the part of the tool holder to which the automatic tool changer is attached
when the tool holder is moved from the tool changer to the spindle.
 The collet pocket is the area into which the collet is inserted before being secured by
various types of collet nuts.

Chapter 6
Machining phase for each part position (detail and justification of
parameters)

6.1 Rough/rerough
The part was obtained through 7 milling operation and 4 drillings. Those operations are
as follows.
1st Process
2nd Process

3rd Process
4th Process
5th Process

6.2 Finishing
-

6.3 Remachine/clean up, pencil

-
 6.4 Drilling /Taping
Drilling procedure was done as follows:
 Chapter 7
Postprocessing, NC file analysis

Post processing was exported and saved with the rest of the documents.
 Chapter 8
Reports

Here are shown all the NC reports from the program.