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Reduction of manual finishing by automated manufacturing of dies and moulds (AMADEUS)

Deliverables

The designed belt grinding device is a tool which can be used in a milling machine like a normal cutting tool. The device has a modular design so that it can be easily adapted to milling machines with different interfaces. The use of device is the improvement of the roughness of a work piece after milling in one set up. The belt grinding device can be changed manually as well as automatically from a pick-up station into the milling machine. During the course of the project, two prototypes have been produced by SATB with interfaces for three different milling machines. These prototypes are available for further research work. The device is equipped with features for an easy installation on different spindle noses of milling machines. It runs with high precision and - in spite of its size - nearly free from vibrations. Due to the modular design and the use of standard elements the device can be produced for a reasonable cost. Best grinding results are achieved in dry grinding without cooling agents. As it is possible to work with one grinding belt throughout a complete work cycle, there is no need to change the grinding belt during the grinding operation. The most important part of the device is a gear box with special toothed wheels. The gear box is maintenance-free.
The software library delivers a complete stand-alone CAM-System generating the tool paths for the belt grinding operation. The CAM-System is fed with a geometric description of the work piece surface and the data of the belt grinding tool. A special highlight of the system is the possibility to add data from work flow simulations for an intelligent tool-path generation. The system assists the choice of grinding technology in general (e.g. grinding in flow-direction or perpendicular to the flow-direction). It also assists a smooth approach of the grinding tool and work piece, analyses the overlapping of grinding tracks and the special behaviour in sophisticated parts of the surface. A grinding simulation is part of the system to detect errors and problems. The system produces a CL-data file that can be processed by the CAM-systems of each company and their post processors. This allow an automatic tool-path generation without expensive modifications of the CAM systems on market.

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