document: Process planning for reliable high-speed machining of moulds A method of generating NC programs for the high-speed milling of moulds is investigated . Forging dies and injection moulds , whether plastic or aluminium , have a complex surface geometry . In addition they are made of steels of hardness as much as 30 or even 50 HRC . Since 1995 , high-speed machining has been much adopted by the die-making industry , which with this technology can reduce its use of Sinking Electrodischarge Machining -LRB- SEDM -RRB- . EDM , in general , calls for longer machining times . The use of high-speed machining makes it necessary to redefine the preliminary stages of the process . In addition , it affects the methodology employed in the generation of NC programs , which requires the use of high-level CAM software . The aim is to generate error-free programs that make use of optimum cutting strategies in the interest of productivity and surface quality . The final result is a more reliable manufacturing process . There are two risks in the use of high-speed milling on hardened steels . One of these is tool breakage , which may be very costly and may furthermore entail marks on the workpiece . The other is collisions between the tool and the workpiece or fixtures , the result of which may be damage to the ceramic bearings in the spindles . in order to minimize these risks it is necessary that new control and optimization steps be included in the CAM methodology . There are three things that the firm adopting high-speed methods should do . It should redefine its process engineering , it should systematize access by its CAM programmers to high-speed knowhow , and it should take up the use of process simulation tools . In the latter case , it will be very advantageous to use tools for the estimation of cutting forces . The new work methods proposed in this article have made it possible to introduce high speed milling -LRB- HSM -RRB- into the die industry . Examples are given of how the technique has been applied with CAM programming re-engineered as here proposed , with an explanation of the novel features and the results
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extractive_keyphrases: moulds process planning nc programs forging dies complex surface geometry optimum cutting strategies productivity surface quality hardened steels tool breakage ceramic bearings cam methodology process simulation tools
abstractive_keyphrases: reliable high-speed machining high-speed milling injection moulds error-free programs tool workpiece collisions process engineering redefinition cam programming re-engineering cutting strategies