Development of a Computer-Aided Manufacturing System for Profiled Edge Lamination Tooling

Profiled Edge Lamination (PEL) tooling is a promising Rapid Tooling (RT) method involving the assembly of an array of laminations whose top edges are simultaneously profiled and beveled based on a CAD model of the intended tool surface. To facilitate adoption of this RT method by industry, a comprehensive PEL Tooling Development System has been proposed. The two main parts of this system are (1) iterative tool design based on thermal and structural models and (2) fabrication of the tool using a Computer-aided Manufacturing (CAM) software and Abrasive Water Jet (AWJ) cutting. CAM software has been developed to take lamination slice data (profiles) from any proprietary RP software in the form of polylines and create smooth, kinematically desirable cutting trajectories for each tool lamination. Two cutting trajectory algorithms, called Identical Equidistant Profile Segmentation (IEPS) and Adaptively Vectored Profiles Projection (AVPP), were created for this purpose. By comparing the performance of both algorithms with a benchmark part shape, the AVPP algorithm provided better cutting trajectories for complicated tool geometries. A 15-layer aluminum PEL tool was successfully fabricated using a 5-axis CNC AWJ cutter and NC code generated by the CAM software.

CAM Software Development for Laminated Tooling: Lamination Cutting Trajectory Algorithms

This paper addresses the research and development of a Computer-Aided Manufacturing (CAM) software package used for fabricating Profiled-Edge Lamination (PEL) tooling. Background research in PEL tooling is reviewed and possible applications for PEL tooling in seven different manufacturing processes are examined. The general PEL tooling process is outlined and the fundamental role that the CAM software plays in this process are discussed. The CAM software is used to create and simulate appropriate line-of-sight cutting trajectories for an Abrasive Water Jet (AWJ) cutting machine. Using this CAM software, PEL cutting trajectories and the resulting PEL tool shape can be compared with the original CAD tool shape. After the tool shape is evaluated, the CAM software exports CNC G-code to an AWJ cutting machine for cutting individual laminations. Four algorithms have been developed to create suitable cutting trajectories for PELs. Each algorithm is evaluated through simulation using the benchmark tool shape. As a result of this evaluation, one particular algorithm was found to be the most promising because it 1) successfully produces sharp edges with no loss of original shape, 2) allows unlimited tool orientation, and 3) better handles complicated tooling geometries. Finally, future work to validate the cutting trajectory algorithms is outlined.