Master Die Tool Iterative Reworking via CT Measurement
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Solution Overview
Problem
Existing methods for producing master die tools result in unpredictable deviations from the intended component shape due to shrinkage, requiring complex and time-consuming measurement processes and manual reworking, which limits the accuracy and efficiency of component production.
Innovation Solution
An automated method and device that utilize computer-controlled machine tools and computed-tomography-based coordinate measuring appliances to iteratively modify the surface model of the master die tool, ensuring that the produced components match the CAD model within predefined tolerance levels, reducing the need for manual intervention and simplifying the production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If master die tools are produced by computer-controlled machine tools using CAD models, then production efficiency is improved, but manufacturing precision deteriorates due to unpredictable shrinkage deviations
Solution Approach 1:
The patent implements a feedback mechanism where the produced component is measured against the CAD model using coordinate measuring appliances, and the deviations are fed back to automatically adjust and rework the master die tool. This closed-loop system corrects shrinkage deviations and ensures manufacturing precision while maintaining high productivity.
Solution Approach 2:
The patent changes the parameters of the master die tool based on measured deviations from the CAD model. By automatically adjusting the tool's dimensions and geometry parameters through computer-controlled reworking, the system compensates for shrinkage effects and achieves the required component accuracy.
2Manufacturing precision
If manual measurement and reworking of master die tools is performed, then manufacturing precision is improved, but device complexity and production time increase
Solution Approach 1:
The patent replaces manual mechanical measurement and reworking operations with automated computer-controlled systems. Coordinate measuring appliances and computer-controlled machine tools perform the measurement and adjustment tasks automatically, reducing device complexity and production time while maintaining or improving manufacturing precision.
Solution Approach 2:
The patent uses digital copies of the master die tool in the form of CAD models to store and transmit geometric information. This digital copying enables precise measurement and adjustment without repeated physical measurement and reworking, simplifying the process and reducing time consumption.
3Manufacturing precision
If multiple iteration steps are used to adjust the master die tool, then manufacturing precision is improved, but productivity deteriorates due to extended production time
Solution Approach 1:
The patent performs preliminary actions by automatically adjusting the master die tool parameters based on predicted shrinkage behavior and initial measurements. This allows the system to reach the required precision in fewer iteration steps by proactively correcting deviations rather than reactively adjusting after each measurement cycle.
Solution Approach 2:
The automated feedback system continuously monitors and adjusts the master die tool, enabling the system to converge on the correct dimensions more rapidly. By using computational algorithms to process measurement data and generate adjustment commands, the system reduces the number of iteration steps needed compared to manual adjustment processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method significantly reduces iteration steps and allows for the production of components that accurately match the CAD model, improving the efficiency and accuracy of component production by automating the adjustment of the master die tool based on real-time measurements, often requiring only a single iteration step.
Implementation Method 1
the component is generally arranged on a rotary table and irradiated by X-ray radiation from different directions by rotating the rotary table into different rotational positions. However, other examination arrangement geometries are also possible and known. The radiation attenuated by extinction in the material of the component or workpiece is detected in a spatially and temporally resolved fashion by a sensor apparatus.
Data Source
AI summary
A device and a method for the production of a master die tool for a component. The method includes the following steps: a) receiving or creating a CAD model of the component; b) deriving a surface model for the master die tool based on the CAD model of the component; c) creating the master die tool with NC machines using the surface model; d) producing an entity of the component using the master die tool; e) detecting the contours of the entity of the component by way of a computed tomography-based coordinate measuring device which supplies a 3D point cloud of surface points of the entity of the component; f) comparing the 3D points of the 3D point cloud to the CAD model, and determining whether any deviations exist beyond predetermined tolerance thresholds, and if this is the case g) modifying the surface model based on the deviations detected; h) reworking the master die tool or recreating the master die tool with the NC machines based on the modified surface model; i) repeating steps d) to h) until no more deviations exist beyond the predetermined tolerance thresholds.