Surface Structuring and Tool Path Planning for Efficient Milling of Dies

Zabel, A.1, a; Surmann, T.1, b; Peuker, A.1, c

Institut für Spanende Fertigung, Technische Universität Dortmund, Baroper Str. 303, 44227 Dortmund

a); b); c)


The use of high-strength sheet metals in structural and body parts in the automotive industry is inevitably increasing tool wear of deep-drawing dies. To improve wear resistance, hard coatings can be applied by arc spraying. These coatings stick to the surface by means of a purely mechanical connection. Standard finish milling processes with ball end mills do not provide a sufficient surface roughness for a grouting between coating and die. Therefore a special structuring of the tool surface becomes necessary. The tool coating is an additional step within the process chain. To compensate for the extra time and effort, the actual milling process has to be more efficient. This can be achieved by using optimized five-axis roughing strategies and integrating tool structuring in the finishing process with appropriate milling tools. To maintain a high degree of process safety when applying high performance cutting parameters, a multi-scale milling simulation is developed.


Surface Structuring, High Feed Milling, Tool Path Planning, Milling Simulation


In: 7th International Conference on High Speed Machining Proceedings, 2008, Bamberg, Abele, E. (Hrsg.), ISBN 978-3-87525-274-3, S. 155-160