Latest Capabilities And Features In CAD/CAM Systems And Additive Manufacturing Technologies For Dies And Tooling Are Discussed In The Essay.

1. Discuss the latest capabilities and features in leading commercial CAD/CAM systems in production of tooling and dies.
2. Discuss the latest additive manufacturing technologies used in fabrication of dies for injection moulding.

Capabilities and Features of CAD/CAM Systems

Computer aided design and Computer aided Manufacturing (CAD/CAM) are the software used for Making 2d, 3d solid model (AutoCAD, Catia, Solid works etc.) and manufacturing Like (Delcam, Mastercam).Software is used to increase the productivity and quality of the manufacturing products.

CAM software CAM software 

The Creo software is developed by parametric technology corporation limited. That we are using is one of the most preferable and easy to use software it can perform wide range of tasks like Part modelling, Drafting, Assembly, moulding and NC machining,

Now a days plastic parts are Replace the aluminium and steel part because plastic part have Low density, high strength and Low weight. The plastic part have the low weight in comparison to aluminium and steel that’s why the decrease over all vehicle weight. Due to decreasing the vehicle weight efficiency of engine increase.  Plastic part which is widely used in industries for making Logo of vehicle, making Housing of mirror and mobile phones the design of the mobile top cover was from early 20th century. In this report, we have made the sketch of the front part Logo of vehicle and extruded it into 3d part and then we have made its mould and separated core and cavity for performing NC machining of these moulds and finally we have generated G-codes for volume milling and surface milling for both Cavity and core for Computer aided manufacturing. This report contains detailed explanation of every step that is used generate 3d part, moulding and NC machining. 

The procedure followed for designing the part in Creo 3.0 parametric is as follows:

Sketch

Step 1- Open Creo parametric 3.0 then select new from the file window and select part and

Solid and then UN tick the box below of default template and choose mmns_ part _solid and then click ok.

Step 2- Select the sketch command and then select the Front plane and start your sketch as per your dimension. after finishing sketch come out from sketch mode. 

Step 4-select extrude command.

Extrude command is used for adding the material or thickness to sketch.

Extrude the sketch 5mm. extrusion method symmetric (mid plane).

Step-5 Select sketch command than select surface of object for sketching the inner part. 

Step 6-Exit from sketch mode and select extrude command for adding material to sketch. Give extrusion length 5mm because in previous part we 5mm thickness.  

Now our desired part is ready for mould. 

Additive Manufacturing Technologies for Injection Molding Dies

After creating 3d part now the next process is to create a mould Core and cavity for the given part. The moulding consists of following steps: -

• Preparing and analysing design model.
• Creating the mould model.
• Creating the parting surface.
• Creating mould component.
• Filling and opening the mould.

There are different methods for creating mould. It depends on designer which method he prefers. In some methods we directly work in mould tools. And in another method we work in assembly mode (cut out) and create mould for the objects.

In this assignment i took cut out method for creating mould core and cavity.

Now, the detailed steps for creating mould is explained below. 

Step 1- Click on the new tab, select Assembly and solid assembly and UN tick the default Template and choose mmns_ asm_nc and click ok. As shown in 

Step 2-insert your model by click on assemble -select your part from computer and give the constraint default. 

Step 3- Click on “create”, it helps you to create part in assembly mode. After clicking on create a pop up window will open then click ok. After this another popup will open then click on copy from existing then click ok. It will create same another part in assembly and it will shows in model tree. 

Step 4- select mid plane from model tree and create a rectangle for cavity back plate. you can create a rectangle of any dimension you want. That rectangular part will be you core or cavity back plate. Create sketch and extrude it 2.50mm.

Step 5 after creating extruded part click on component then select component operation. After clicking on component operation a menu will be open in side in this menu select “cut out”

And then select back plate click ok. Then select the part which impression you want.

Our core part is ready, now we have to create cavity part. The process for crate cavity will be same as core

Step 6: Click on “create”, it helps you to create part in assembly mode. After clicking on create a pop up window will open then click ok. After this another popup will open then click on copy from existing then click ok. It will create same another part in assembly and it will shows in model tree. 

Step 7: select front face of core part and create a rectangle for cavity back plate. You can create a rectangle of any dimension you want. That rectangular part will be you core or cavity back plate. Create sketch and extrude it 2.50mm opposite to core part.

Design Methodology

Step 8: after creating extruded part click on component then select component operation. After clicking on component operation a menu will be open in side in this menu select “cut out”

And then select back plate click ok. Then select the part which impression you want. 

Now core and cavity is ready. 

Step 9: to explode core and cavity in two part click on “edit position” and then click on core or cavity and drag them outwards. Mould is ready. Click on core part or cavity part and open it in part mode and save it for manufacturing process. 

Once the mould part is completed and the mould is separated into core and cavity. Now we will do milling operation on core and cavity separately. First, we will start with core section of the mould part.

Core:-

Step1 - Click on the new tab, select manufacturing and NC assembly and UN tick the default

Step2 – click on the reference model option and then select assemble model now choose the core part of the moulding will appear 

Step 3 - Now we will define work centre. Click on work centre and select mill option then a pop up window will appear in that choose number of axes 3axis then click ok.  

Step 4- Now we will select the co-ordinate system, by selecting two side edges and one upper surface and we have to make ensure that the Z direction is pointing upwards. 

Step 5- Select the operation option, now select the co-ordinate system, click on clearance

Option and in clearance option select the type to plane and give the reference top surface and give the value 50 and tolerance 1.  

Step 6- Click on work piece option and set it to automatic work piece.  

Step 7- Now we have to give operation so we have to define the machine as zero and select the co-ordinate systems as ACS0. Then we will define retract plane after that a mill tab will appear now from the mill window icon we have to select roughing icon and in roughing icon select volume rough. After that give, the tool diameter 5 and length as 100. 

Step 8 – After setting the parameters of roughing now select the volume milling option and give the following parameters

Cut feed-200

Step depth-0.5

Step over-1

Clear distance-1

Spindle speed-1000rpm. 

Step 9 – Now right click on the volume milling option from model tree and select play path. 

Molding Process

Step 10 – Now we have to save the CL file to generate the G-Codes. Now a tap file will be Created which can be open in notepad and the codes are given below for volume milling.

%

N0005 (FADAL VMC 6030 - VH65)

N0010G90G40G80

N0015T1M6

N0020S1500M3

N0025G0X146.2527334866 Y135.8405379475

N1825G1Z-18.09

N1830G3X-2.3400000000

GOTO Y 89.7591000659

N1835G1Z28.02

N1840M5

N1845M2

%

Step 10: for creating NC code for cavity we have to follow the same process. beacuse core and cavity have the same dimensions and parameters.

Step1 - Click on the new tab, select manufacturing and NC assembly and UN tick the default

Template and choose mmns_mfg_nc and click ok.  

Step11 – click on the reference model option and then select assemble model now choose the core part of the moulding will appear 

Step 12 - Now we will define work centre. Click on work centre and select mill option then a pop up window will appear in that choose number of axes 3axis then click ok.  

Step 13- Now we will select the co-ordinate system, by selecting two side edges and one upper surface and we have to make ensure that the Z direction is pointing upwards.

Step 14- Select the operation option, now select the co-ordinate system, click on clearance

Option and in clearance option select the type to plane and give the reference top surface and give the value 50 and tolerance 1.   

Step 15- Click on work piece option and set it to automatic work piece. 

Step 16- Now we have to give operation so we have to define the machine as zero and select the co-ordinate systems as ACS0. Then we will define retract plane after that a mill tab will appear now from the mill window icon we have to select roughing icon and in roughing icon select volume rough. After that give, the tool diameter 5 and length as 100.  

Step 17 – After setting the parameters of roughing now select the volume milling option and give the following parameters

Cut feed-200

 Step depth-0.5,

Step over-1

Clear distance-1

Spindle speed-1000rpm. 

Step 18 – Now right click on the volume milling option from model tree and select play path.

Step 19 – Now we have to save the CL file to generate the G-Codes. Now a tap file will be

Created which can be open in notepad and the codes are given below for volume milling.

N0005 (FADAL VMC 6030 - VH65)

N0010G90G40G80

N0015T1M6

N0020S1500M3

N0025G0X146.2527334866 Y135.8405379475

N1825G1Z-18.09

N1830G3X-2.3400000000

GOTO Y 89.7591000659

N1835G1Z28.02

N1840M5

N1845M2

%

1. According to Mohd Jamsheeda, Md Aaqib Rahmanb, M.A .Moyeedc, G.M. Sayeed Ahmedd. Modelling in done by using Unigraphics (NX 7.5) and Auto Desk Mould flow Plastic Insight is use for Mould flow Analysis for CAM BUSH filling rate, system for cooling location and gate Location for submarine. The moulding tool have the Cavity plate, bottom plate, Core plate, Top plate, Spacer blocks, Ejector pin,  Ejector plate and the Bottom plate. The part of injection moulding has designed and analysed. Submarine gate and Baffle circular Hole cooling system has provided in the moulding tool to increase and surface finish the productivity. Cam bush component use the material Nylon-66 for moulding tool with the various parameters of injection moulding machine (Md, et al., 2015).
2. According to B., Yilmaz; A., NekoraAzak; G., Alp; H., Ek?i Computer-aided design (CAD) and computer-aided manufacturing (CAM) technology is accessible for the fabrication of complete Part and substitute to conventional fabrication methods. Report describes a work flow for a technique that combines the use of conventional impressions and maxillomandibular relationship records with CAD-CAM technology for the fabrication of maxillary and mandibular complete dentures. (B., et al., 2016)
3. According to J.Goodacre, Brian; J.Goodacre, SaCharles; Z.BabaDMD, MSDbNadim; T.KattadiyilDDS, MSDcMathew ranking of results depend on medium and interquartile range find that the precision and reproducibility of the CAD-CAM method was more reliably limited around zero at 3 of the 5 locations. Therefore, the CAD-CAM method showed the best grouping of accuracy and reproducibility between the corroborated fabrication techniques. The pack and press method was more correct at 2 of the 5 positions; however, its interquartile variety was the highest of the 4 tested dispensation methods. The pour method was the best reproducible at 2 of the 5 locations; however, its accuracy was the lowermost of the tested methods. (J.Goodacre, et al., 2017)
4. RP and manufacturing method has shown a high potential to decrease the cycle and cost of New product development. Computer aided design and computer aided manufacturing systems have been developed and implement remote products and manufacturing for RP and increase the ability of RPD for a large quantity of small and medium size enterprise. This Articles make availability to inclusive review of new research Computer aided design and computer aided manufacturing systems. The key issues and enabling tools to implement the remote RP&M systems, involve CAD, CAM and CAE, Modelling, Optimization, Algorithms, Dimension of anisotropic, STEP/XML, Smearing new skills and ideas to RPS , are defined in detail. Finally, this review gives viewpoint on promising future growth and research way for CAD, CAM, RP&M systems. (A.K., et al., 2015)
5. According to Diogo, Pedrollo L.,V., Ende A.; J., Munck, Yumi Umeda, S. Thaís; Clovis Cardoso, V. Luiz Only following a ‘2.5-mm deep endocrown’ design, composite seemed more favorable Comparison to lithium disilicate glass-ceramic as crown related product. this may be clarified by their dissimilarity in elastic modulus (Diogo, et al., 2017)
6. According L., Ciocca; R., Mingucci, Gi. Gassino; R., ScottiMD describes a method to make an implant-retained maxillofacial prosthesis using CAD, CAM skill and a RP Machine. The Main advantage of this technique is virtual 3-D integration of the faulty surface with the reflected and digitalized normal ear. Creating an impress of the faulty side is not essential, because only the location of the implantations must be recorded to grow the bar for the retaining of the prosthesis. This technique allows positioning of the ear straightforward onto the computer screen, eliminating the analytic waxing, and the manufacture of the stone mould is not necessary because of the rapid prototyping process. (L., et al., 2007)
7. O. car, B. Yilmaz; S., HanAltintas When undefended to hot and cold coffee, the colour change was beyond clinical suitability for the tested resin nano ceramic and nano composite resin materials. The average colour modification of the hybrid ceramic was clinically perceivable over the confirmed thickness values. The colour change of lithium disilicate ceramic was not clinically perceivable at any tested thickness. (O., et al., 2016)
8. The Main contribution of the work is to develop an intelligent structure for manufacturing features in the part of CAD and CAM. It takes the design and engineering phase composed in design phase and provides an intelligent border between Design and Manufacturing data by developing a library of features. The library is called engineering feature library which is linked with commercial CAD/CAM software package named Creo Elements/Pro by toolkit. Confidential the library, developed features are organised hierarchically. A methodical database system also have been developing and analysing for each feature consists of parameterised geometry, manufacturing data like machine tool, cutting tools, recommended tolerances and surface finishing values, etc. Design limits, functionality rules, and Design-for-manufacture rules. The method has been useful in two case studies in which a rotating part (shaft) and a non-rotating part are designed by manufacturing features. Therefore, from manufacturing feature collection a design can create entirely in a bottom-up manner using manufacturing entities in the same way as they would be created through the manufacturing phase. Upon supplement of a feature, the system confirms that no functionality or manufacturing rules are violated. Designers are advised if they attempt to include features that disrupt Design-for-manufacture and Design functionality rules. If a feature is modify, the system confirms the feature by making sure that it remains stable with its original functionality and Design-for-manufacture rules are re-applied. The system will be aided the process planner and manufacturing engineer by automatically generating work-piece data structure. (A.S.M., et al., 2013)

Conclusion and Discussion

The initial indication was comparatively ambitious, and acquired a little longer to scale back comparatively I hoped .By the Using of Computer aided designing, computer aided manufacturing and computer aided engineering software we can easily Develop the product, manufacturing the product and analysis the product. It is great for analysing by the using of analysis software we can easily analyse but before it, analyse not possible it is done hit and trial method for analysing the load and CFD analysis.

References

A.K., M., Ranga, R. D. & K.N.S., S., 2015. The Integration of CAD/CAM and Rapid Prototyping in Product Development: A Review. Materialstoday, pp. 3438-3445.

A.S.M., H., P.K., H., M.S., P. & T., S., 2013. Computers & Industrial Engineering. Integrated manufacturing features and Design-for-manufacture guidelines for reducing product cost under CAD/CAM environment, pp. 988-1003.

B., R., S., R. & J., P., 2016. Revista Portuguesa de Estomatologia, Medicina Dentária e Cirurgia Maxilofacial. Reparability of two different CAD/CAM polymer materials using a light-cured composite and universal adhesives, pp. 189-196.

B., Y., A., N., G., A. & H., E., 2016. Use of CAD-CAM technology for the fabrication of complete dentures: An alternative technique. pp. 140-143.

Diogo, P. L. et al., 2017. Journal of Dentistry. Biomechanical behavior of endodontically treated premolars using different preparation designs and CAD/CAM materials, pp. 54-61.

J.Goodacre, B., J.Goodacre, S., Z.BabaDMD, M. & T.KattadiyilDDS, M., 2017. The Journal of Prosthetic Dentistry. Comparison of denture base adaptation between CAD-CAM and conventional fabrication techniques, pp. 249-256.

L., C., R., M., Gi., G. & R., S., 2007. The Journal of Prosthetic Dentistry. CAD/CAM ear model and virtual construction of the mold, pp. 339-343.

M., H., S., C. & K.Bansal, N., 2017. The Journal of Prosthetic Dentistry. Interproximal distance analysis of stereolithographic casts made by CAD-CAM technology: An in vitro study, pp. 624-630.

Md, J. M., A., R., M.A., M. & G.M., S., 2015. Design and Analysis of Plastic Injection Mould for CAM BUSH with Submarine Gate. pp. 2083-2093.

O., c., B., Y. & S., H., 2016. The Journal of Prosthetic Dentistry. Color stainability of CAD/CAM and nanocomposite resin materials, pp. 71-75.