A study on the computer-aided measuring integration system for the sheet metal stamping die

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Journal of Materials Processing Technology 177 (2006) 138–141

A study on the computer-aided measuring integration

system for the sheet metal stamping die

Chen-Hua She

a,∗

, Chun-Cheng Chang

a

, Yung-Chou Kao

b

, Hsin-Yu Cheng

c

aDepartment of Mechanical and Automation Engineering, Da-Yeh University, 112 Shan-Jiau Road, Da-Tsuen, Chang-Hua 515, Taiwan bDepartment of Mechanical Engineering, National Kaohsiung University of Applied Sciences, Kaohsiung City 807, Taiwan cDepartment of Mold and Die Engineering, National Kaohsiung University of Applied Sciences, Kaohsiung City 807, Taiwan

Abstract

In this paper, based on the requirements of the design and manufacturing characteristics, a CAD-based CMM (coordinate measuring machine) software and analysis system for the sheet metal stamping die is developed. The system can analyze the NURBS die surface model in IGES format and generate the measuring program in DMIS format as well as the probe path simulation. Moreover, the proposed system has developed the window graphical interface which shows the measuring position and dimensional error through the integration of the die CAD model and measurement information. It can not only be used to diagnose the die quality, but also improve the shop floor process and provide the die polishing guidance. Real measurement of a set of industrial sheet stamping dies on a CMM validates the effectiveness of the developed system.

© 2006 Elsevier B.V. All rights reserved.

Keywords: Stamping die; Coordinate measuring machine; Die diagnosis

1. Introduction

Mold and die industries are mass technology and high value-added industries. The importance of the quality of the mold and die on industrial competitiveness is growing and the measur-ing technology has become an important issue. As compared to the traditional layout machine, the coordinate measuring machine (CMM), which is equipped with touch-trigger probe and can inspect the manufacturing errors of the dedicated prod-uct more precisely and rapidly using the computer numerical control method, has been used widely in the industry. However, most of the measured data remain as the identification of the qualified geometric dimensions or designed points, and cannot provide useful information for the die tryout.

The shapes of mold and die are often designed by sculptured or free-form surfaces with variable curvature by higher-degree polynomials. Conventionally, master models are necessary for die making process and hand engraved by the engraver. The final dies and molds are then machined on a contour milling machine, which uses a master model to guide the cutter. During the die making process, the final dies and stamps do not usually coincide with the curves traced on the drawing board due to the inaccuracy

Corresponding author. Tel.: +886 4 8511888x2121; fax: +886 4 7554175.

E-mail address:chshe@mail.dyu.edu.tw(C.-H. She).

of machining and master model. The advent of computer-aided geometric design dramatically solved this problem. The dies and molds can be produced directly by the computer numerical control (CNC) machine together with the computer-aided design (CAD) and computer-aided manufacturing (CAM) software.

Measurements of free-form surfaces are difficult using a CMM with the teach mode since the surface normal direction of the probing point should be calculated to compensate the probe’s diameter. It is necessary to employ CAD-directed techniques to generate the probing points and probing paths. Various studies [1–4]have addressed the issue of developing a CMM inspection path planning and relatively few studies[5]have addressed the development of the CMM system dedicated for the stamping die to the best of the author’s knowledge. On the other hand, most of current commercial CMM packages such as PC-DMIS[6], CAPPS[7], CAMIO[8]and SILMA[9]support CAD-directed inspection planning. However, they are general purpose pack-ages designed for various components represented by free-form surfaces, and are expensive.

In this study, a CAD-based CMM software and analysis sys-tem for the sheet metal stamping die will be developed. The developed system can analyze the CAD model of the stamp-ing die with NURBS (non-uniform rational B-spline) surface in IGES (initial graphics exchange specification) format and gener-ate the neutral measuring program in DMIS (dimensional mea-suring interface specification) format. Moreover, the proposed 0924-0136/$ – see front matter © 2006 Elsevier B.V. All rights reserved.

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C.-H. She et al. / Journal of Materials Processing Technology 177 (2006) 138–141 141

Fig. 4. The graphical output of the measured result.

error and the surface normal direction. Note that the points shown in red colour, e.g. P1, P3, P4,. . . ,P22, are out of tol-erance. If the user clicks the “View NG Point” button, only the NG points will be displayed. Once the punch and the die are mea-sured, the “Spotting Clearance” button can combine the data for the punch and the die to calculate the spotting clearance. In gen-eral, the die maker repairs the stamping die on the spotting press using the red lead and hand repair tool. Since the spotting pro-cedure is usually performed many times, the spotting clearance is the important guidance for the die tryout.

6. Conclusion

A computer-aided measuring integration system for the sheet metal stamping die has been successfully developed, imple-mented and verified on an industrial stamping die. The proposed system is a CAD-based CMM software and analysis system that can analyze the NURBS surface and generate the DMIS output program. The CAD model of the die, the probe path and the projected dimensional error can be dynamically shown on the screen using the OpenGL language to assist the user to view the results easily and quickly. The result of this study can shorten the time-to-market effectively and increase the competitiveness for the mold and die industry.

Acknowledgements

The authors are grateful to the National Science Council of Taiwan and Drewloong Precision Machinery for supporting this

research under grant NSC 91-2622-E-212-009-CC3 and NSC 92-2622-E-212-012-CC3. The authors also would like to thank Jui-Li Enterprise for use of the CMM equipment and stamp-ing die. Thanks are also extended to graduate students Mr. Chen-Chih Yang and Mr. Ho-Pao Chang for their experimen-tal assistance.

References

[1] I. Ainsworth, M. Ristic, D. Brujic, CAD-based measurement path plan-ning for free-form shapes using contact probes, Int. J. Adv. Manuf. Technol. 16 (2000) 23–31.

[2] S.G. Zhang, A. Ajmal, J. Wootton, A. Chisholm, A feature-based inspection process planning system for co-ordinate measuring machine (CMM), J. Mater. Process. Technol. 107 (2000) 111–118.

[3] Y.J. Lin, P. Murugappan, A new algorithm for determining a collision-free path for a CMM probe, Int. J. Mach. Tools Manuf. 39 (1999) 1397–1408.

[4] C.P. Lim, C.H. Menq, CMM feature accessibility and path generation, Int. J. Prod. Res. 32 (3) (1994) 597–618.

[5] H.T. Yau, C.H. Menq, Automated CMM path planning for dimensional inspection of dies and molds having complex surfaces, Int. J. Mach. Tools Manuf. 35 (6) (1995) 861–876.

[6] PC-DMIS V3.2 for Windows Reference Manual, Brown & Sharpe, 2001.

[7] CAPPS Homepagehttp://www.capps-edges.com.

[8] CAMIO Homepagehttp://www.lk-cmm.com/software products.asp. [9] SILMA Homepagehttp://www.silma.com.

[10] L. Piegl, W. Tiller, Curve and surface constructions using rational B-splines, Comp. Aided Des. 19 (9) (1987) 609–616.

數據

Fig. 4. The graphical output of the measured result.
Fig. 4. The graphical output of the measured result. p.2

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