An Algorithm of Tool-Path Optimization for High-Speed Machining Deep-Cavity Precision Forging Die

Aiming at the difficulty of maintaining the contour precision of forging die with deep pocket, an optimization algorithm of tool-path generation for high speed machining (abbr. HSM) forging die with deep cavity is proposed in this paper. In terms of measuring errors of pocketing die, a mathematical model correlation to the length of a tool-path, the available length of a cutting tool and the profile errors are characterized. After the calculation of the profile errors that vary with the length of the tool-path, the helix shaped tool-path can be created. Moreover, the optimized tool-path based on the algorithm for machining die with deep cavity is also generated by using the smooth curve as transition tool-path. Depending on the Mikron Duro800 HSM Machine Tool, a precision cavity of forging die for shaping internal-star-wheel parts can be machined. The experimental results indicate that the profile precision based on the optimum algorithm has been improved by IT 1~2.