Decision algorithm for selection of high-speed machining, EDM or a combination for the manufacture of injection moulds

Abstract

The paper presents the development of a decision algorithm for a prototype computer-aided process planning system IMOLD_CAPP for the manufacture of an injection mould. A combination of a generative and plan template approach is used for the development of the system. The input to the system is a 3D solid model developed using IMOLD™. Successful implementation of the prototype IMOLD_CAPP depends on its incorporation to an appropriate machining algorithm. Unfortunately, there is no one standard algorithm to choose the appropriate machining process from high-speed machining (HSM), electrical discharge machining (EDM) or a combination of the two. Consequently, this research undertook the development of a decision algorithm for the selection of the appropriate machining process. The algorithm decides whether HSM, EDM or a combination should be chosen for a particular case. Several case studies are conducted and the economics of these processes have been analysed to verify the suitability of the algorithm.