Development of the new technology of machining, measuring and control for advanced manufacturing system of metal molds

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Recently, the automated system for the manufacturing process of metal molds become important. The purpose of this research is to develop the advanced manufacturing system of metal molds by integrating the machining, measuring and control technology for metal molds. The results obtained in this research are summarized as follows.(1) The motion of rotary polishing tools for finishing of mold surface is simulated, and the availability of rotary polishing tools for automated machining of metal molds is discussed.(2) The electrolytic polishing is applied to the finishing process of metal molds.(3) A polishing robot which has an on-line constant force control system is proposed. Fuzzy theory is applied to control the movement of the polishing robot. The attitude angel of the robot arm to the polishing surface is automatically determined by sensing the polishing force.(4) An automatic polishing system, which avoids the interfere by generating the polishing route from CAD data, is developed, and its performance is evaluated.(5) A three dimensional optical form sensor is developed. The non-contact measurement of mold surface is carried out, and the performance of developed optical sensor is evaluated.(6) An optical sensor for measurement of surface roughness is developed. The non-contact measurement test of mold surface roughness is carried out, and the performance of the developed optical sensor is evaluated.(7) An expert system for the determination of polishing tools is developed.