Table of Contents

ABSTRACT

The selection of appropriate milling tool diameter and cutting strategies for the production of dies is a multi-parametric problem, which is heavily experience-based. Final decisions are usually taken after several simulation runs on CAM software. This paper describes a fuzzy system, comprising of six fuzzy models. Each model focuses on the solution of a specific problem, namely: the selection of roughing tool diameter, the selection of finishing tool diameter, the need or otherwise for a semi-finishing phase, and the selection of cutting strategy for the three corresponding phases. The input parameters and their membership functions were introduced and created based on data from industrial partners, while the correlation of parameters used for the creation of fuzzy rules were based on CAM simulation results. Breakthroughs in this research are the introduction of a time versus quality criterion, defined according to user intent, and the adoption of a teaching philosophy. The time vs quality criterion allows the user to control the milling process tightly, especially since the finishing process can prove very time consuming if high quality is required. The teaching philosophy enables the user to comprehend the interaction of pertinent parameters and the result of their variation, thus escaping the typical CAM system black-box paradigm. Examples are used to present and discuss the integrity of the system.

Keywords: fuzzy model, tool selection, milling strategy, sculptured surface, die milling.