An integrated approach to the high-speed machining of moulds and dies involving both a knowledge-based system and a chatter detection and control system

Over the past decade, high-speed machining (HSM) has provided a step change in productivity for the manufacture of moulds and dies, particularly those made from tool steels in the fully hardened state. Advantages include reduced machining times and costs and favourable workpiece surface integrity. The knowledge and expertise that have been generated in academia and industry are widespread and important for the efficient utilization of HSM. Following a survey of relevant publications, the present paper details the development of an integrated system for the HSM of moulds and dies. This included the design and implementation of a knowledge-based system (KBS) and a chatter detection and control system. The main modules of the KBS related to machine tools, cutting tools and machinability data, toolholders, cutter path strategies and troubleshooting, together with a database management centre. Ranking techniques were employed with combined weighing factors, together with tool rationalization and reduction strategies, fuzzy logic and machinability data optimization. The chatter detection and control system utilized a microphone to detect chatter and employed online spindle speed and feed rate modification strategies for its suppression. The system was capable of being interfaced with the KBS in order to transfer and store local knowledge unique to a particular toolmaker's operations.