Topological model for machining of parts with complex shapes

Complex shapes are widely used to design products in several industries such as aeronautics, automotive and domestic appliances. Several variations of their curvatures and orientations generate difficulties during their manufacturing or the machining of dies used in moulding, injection and forging. Analysis of several parts highlights two levels of difficulties between three types of shapes: prismatic parts with simple geometrical shapes, aeronautic structure parts composed of several shallow pockets and forging dies composed of several deep cavities which often contain protrusions. This paper mainly concerns High Speed Machining (HSM) of these dies which represent the highest complexity level because of the shapes' geometry and their topology. Five axes HSM is generally required for such complex shaped parts but 3 axes machining can be sufficient for dies. Evolutions in HSM CAM software and machine tools lead to an important increase in time for machining preparation. Analysis stages of the CAD model particularly induce this time increase which is required for a wise choice of cutting tools and machining strategies. Assistance modules for prismatic parts machining features identification in CAD models are widely implemented in CAM software. In spite of the last CAM evolutions, these kinds of CAM modules are undeveloped for aeronautical structure parts and forging dies. Development of new CAM modules for the extraction of relevant machining areas as well as the definition of the topological relations between these areas must make it possible for the machining assistant to reduce the machining preparation time. In this paper, a model developed for the description of complex shape parts topology is presented. It is based on machining areas extracted for the construction of geometrical features starting from CAD models of the parts. As topology is described in order to assist machining assistant during machining process generation, the difficulties associated with tasks he carried out are analyzed at first. The topological model presented after is based on the basic geometrical features extracted. Topological relations which represent the framework of the model are defined between the basic geometrical features which are gathered afterwards in macro-features. Approach used for the identification of these macro-features is also presented in this paper. Detailed application on the construction of the topological model of forging dies is presented in the last part of the paper.