This thesis contents theoretical description of methods for choosing and optimization of cutting conditions for progressive machining technologies. Especially it is concerned on CNC machining. The aim of experimental part of work is to set cutting conditions and simultaneously to achieve the most economical solution under current production conditions of the company. The product must also comply with required quality, roughness of the surface and geometrical precision.

The thesis deals with the reorganization of production injection pump casing, when the existing production solution, using cutting lines, did not meet the requirements for flexible manufacturing. There are handled points leading to the replacement of the line of machining centres after a brief introduction of the company. Among the main points of thesis are the design of operations, choice of tools and cutting conditions, proposal clamping device and technology, techno-economic evaluation of the newly introduced production.

This Master’s thesis deals with the proposal manufacturing technology of a shaft with gears on a CNC machine tool. The first part of the thesis is focused on the concise description selected shaft and its use. In the next part of the thesis are state selected materials, which are suitable used for shafts and gears. After that is create drawing component, suggest technological procedure, tool list and machine list which are suitable used for manufacturing selected shaft. In the final part of the thesis is create a CNC program for manufacturing the shaft on the turning and milling machine. Program is created in software SinuTrain 4.7 for control system Sinumerik 840D. The CNC program is verified by graphics simulation to determine a correct function

Diplomová práce uvádí zakladní popis ručního programování CNC strojů, jeho výhod a nevýhod, možností automatizace. Aplikace CNC obrábění na součásti, její verifikace, vyhodnocení dosažených výsledků.

The arrival on the market of a new kind of CNC machines which can both add and remove material to an object paved the way to a new approach to the problem of repairing damaged components. The additive operation is performed by a Direct Laser Deposition (DLD) tool, while the subtractive one is a machining task. Up to now, repair operations have been carried out manually and for this reason they are errors prone, costly and time consuming. Refurbishment can extend the life of a component, saving raw materials and resources. For these reasons, using a precise and repeatable CNC machine to repair valuable objects is therefore very attractive for the sake of reliability and repeatability, but also from an economical and environmental point of view. One of the biggest obstacles to the automation of the repairing process is represented by the fact that the CAM software requires a solid CAD model of the damage to create the toolpaths needed to perform additive operations. Using a 3D scanner the geometry of the damaged component can be reconstructed without major difficulties, but figuring out the damage location is rather difficult. The present work proposes the use of octrees to automatically detect the damaged spot, starting from the 3D scan of the damaged object. A software named DUOADD has been developed to convert this information into a CAD model suitable to be used by the CAM software. DUOADD performs an automatic comparison between the 3D scanned model and the original CAD model to detect the damaged area. The detected volume is then exported as a STEP file suitable to be used directly by the CAM. The new workflow designed to perform a complete repair operation is described placing the focus on the coding part. DUOADD allows to approach the repairing problem from a new point of view which allows savings of time and financial resources. The successful application of the entire process to repair a damaged die for injection molding is reported as a case study. In the last part of this work the strategies used to apply new material on the worn area are described and discussed. This work also highlights the importance of using optimal parameters for the deposition of the new material. The procedures to find those optimal parameters are reported, underlying the pros and cons. Although the DLD process is very energy efficient, some issues as thermal stresses and deformations are also reported and investigated, in an attempt to minimize their effects.

Over the past few years, manufacturing companies have had to deal with an increasing demand for feature-rich products at low costs. The pressures exerted on their existing manufacturing processes have lead manufacturers to investigate internet-based solutions, in order to cope with growing competition. Today, the availability of powerful and low cost 3D tools, along with web-based technologies, provides interesting opportunities to the manufacturing community, with solutions directly implementable at the core of their businesses and organizations. The wooden sign is custom i.e. each sign is completely different from each other. Mass Customization is a paradigm that produces custom products in masses. A wooden sign is custom in nature, and each sign must be completely different from another. Although process planning for mass customized products is same, the tool path required to CNC machine the custom feature varies from part to part. If the tool path is created manually the economics of mass production are challenged. The only viable option is to generate the tool path automatically; furthermore, any time savings in the tool path lead to better profit margins. This thesis presents the automatic web-based tool path planning method for machining sculptured wooden sign on 3 axis Computer Numerical Controlling (CNC) Machines using optimal and cost-effective milling cutters. The web-based tool path planning strategy is integrate with web-based CAD system to automatically generate tool paths for the CAD model using optimal cutter within desired tolerances. The tool path planning method is divided into two parts: foot print (path along which cutter moves) and cutter positioning. The tool path foot print is developed during design stage from the CAD model based on the type of surface to be machined. The foot print varies from part to part which facilitates the mass customization of wooden sign. After designing foot print, the foot print is discretized into points and the gouge-free cutter position at each of these points is found using "Dropping Method". The Dropping Method where cutter is dropped over the work piece surface, and the highest depth at which cutter can go without gouging the surface is calculated. This is repeated for all the position along the foot print. This tool path planning strategy is developed for ball nose, flat-end and radiused end milling cutter for machining wooden sign. The tool path generated using this method is optimized for machining time, tool path generation time and final surface finish. The bucketing technique is developed to optimize tool path generation time, by isolating the triangles which has possibility of intersection at particular position. The bucketing Technique reduced the tool path computation by 75 %, and made tool path generation faster. The optimal cutter selection algorithm is developed which selects best cutter for machining the surface based on the scallop height and volume removal results. The radiused end milling cutter results in highest volume removal which results in lower machining time compared to ball nose end milling cutters, but the scallop heights is higher. However, the scallop height in the radiused end milling cutter is higher only in few regions which reduces the final surface finish. For a sign, it was found around the boundary of logo, outline of lettering, interface of border and background. Thus, in order to achieve higher surface finish and lower machining time, a separate tool path is developed using "Pencil Milling Technique" which will remove the scallops from the regions that was inaccessible by radiused end mills. This tool path with the smaller cutter will move around the boundary of logo and lettering, and clean-up all the scallops left on the surface. The designed tool path for all the three cutters were tested on maple wood and verified against the actual Computer Aided Design model for scallop height and surface finish. The numerical testing of tool path was carried out on a Custom Simulator, ToolSim and was later confirmed by actually machining on a 3 axis CNC machine. The same sign was machined with variety of milling cutters and the best cutter was selected based on the minimum scallop and maximum volume removal. The results of the experimental verification show the method to be accurate for machining sculptured sign. The average scallop height in a machined using 1/8 th inch radiused end milling cuter and using Pencil tool path on the machined surface is found to be 0.03989 mm (1.5708 thou).

Over the past few years, manufacturing companies have had to deal with an increasing demand for feature-rich products at low costs. The pressures exerted on their existing manufacturing processes have lead manufacturers to investigate internet-based solutions, in order to cope with growing competition. Today, the availability of powerful and low cost 3D tools, along with web-based technologies, provides interesting opportunities to the manufacturing community, with solutions directly implementable at the core of their businesses and organizations. The wooden sign is custom i.e. each sign is completely different from each other. Mass Customization is a paradigm that produces custom products in masses. A wooden sign is custom in nature, and each sign must be completely different from another. Although process planning for mass customized products is same, the tool path required to CNC machine the custom feature varies from part to part. If the tool path is created manually the economics of mass production are challenged. The only viable option is to generate the tool path automatically; furthermore, any time savings in the tool path lead to better profit margins. This thesis presents the automatic web-based tool path planning method for machining sculptured wooden sign on 3 axis Computer Numerical Controlling (CNC) Machines using optimal and cost-effective milling cutters. The web-based tool path planning strategy is integrate with web-based CAD system to automatically generate tool paths for the CAD model using optimal cutter within desired tolerances. The tool path planning method is divided into two parts: foot print (path along which cutter moves) and cutter positioning. The tool path foot print is developed during design stage from the CAD model based on the type of surface to be machined. The foot print varies from part to part which facilitates the mass customization of wooden sign. After designing foot print, the foot print is discretized into points and the gouge-free cutter position at each of these points is found using "Dropping Method". The Dropping Method where cutter is dropped over the work piece surface, and the highest depth at which cutter can go without gouging the surface is calculated. This is repeated for all the position along the foot print. This tool path planning strategy is developed for ball nose, flat-end and radiused end milling cutter for machining wooden sign. The tool path generated using this method is optimized for machining time, tool path generation time and final surface finish. The bucketing technique is developed to optimize tool path generation time, by isolating the triangles which has possibility of intersection at particular position. The bucketing Technique reduced the tool path computation by 75 %, and made tool path generation faster. The optimal cutter selection algorithm is developed which selects best cutter for machining the surface based on the scallop height and volume removal results. The radiused end milling cutter results in highest volume removal which results in lower machining time compared to ball nose end milling cutters, but the scallop heights is higher. However, the scallop height in the radiused end milling cutter is higher only in few regions which reduces the final surface finish. For a sign, it was found around the boundary of logo, outline of lettering, interface of border and background. Thus, in order to achieve higher surface finish and lower machining time, a separate tool path is developed using "Pencil Milling Technique" which will remove the scallops from the regions that was inaccessible by radiused end mills. This tool path with the smaller cutter will move around the boundary of logo and lettering, and clean-up all the scallops left on the surface. The designed tool path for all the three cutters were tested on maple wood and verified against the actual Computer Aided Design model for scallop height and surface finish. The numerical testing of tool path was carried out on a Custom Simulator, ToolSim and was later confirmed by actually machining on a 3 axis CNC machine. The same sign was machined with variety of milling cutters and the best cutter was selected based on the minimum scallop and maximum volume removal. The results of the experimental verification show the method to be accurate for machining sculptured sign. The average scallop height in a machined using 1/8 th inch radiused end milling cuter and using Pencil tool path on the machined surface is found to be 0.03989 mm (1.5708 thou).

No estado do Rio Grande do Sul, estão localizadas importantes regiões de extração e processamento do material gemológico ágata. No Distrito Mineiro do Salto do Jacuí encontram-se as maiores jazidas de ágata do Brasil e do Mundo. No município de Soledade se concentram as principais empresas de beneficiamento e comércio de materiais gemológicos. Apesar da abundância de material, a maioria dos objetos produzidos apresenta baixo grau de inovação, os produtos oferecidos no mercado são muito semelhantes entre si e tem, em comum, a falta de diferencial e de utilização de processos que envolvam tecnologia. A ágata é geralmente exportada em estado bruto ou apresentando baixo grau de aproveitamento. O processamento mais comum, utilizado na maior parte das empresas, é o corte em chapas que posteriormente são lixadas, polidas e tingidas em diversas cores. Entre as empresas pesquisadas no presente estudo apenas uma já utiliza processos envolvendo novas tecnologias. Pode-se afirmar que a pesquisa e estudos que auxiliem em um melhor aproveitamento do material ágata possam representar novas oportunidades de produção de objetos e adornos pessoais (jóias) modificando um cenário onde o design inovador é pouco explorado e apresentado. A metodologia empregada para a realização deste estudo contemplou etapas de conhecimento da realidade dos locais de extração, beneficiamento e comercialização de ágata, avaliação dos processos, ensaio de usinagem convencional CNC, ensaios de usinagem não convencional por jato d’água CNC e desenvolvimento de produtos em formas complexas. Foram realizados vinte e quatro ensaios de usinagem, a análise posterior identifica larguras e espessuras ideais buscando a otimização da matéria-prima. Desta forma foi possível alcançar o objetivo principal nesta pesquisa de realizar o corte de ágata com utilização de tecnologia CNC em peças com formas complexas. / Rio Grande do Sul State, Brazil, has important regions of extraction and processing of agate. Salto Jacuí Mining District, in the central region of this State, is one of the largest and more importante agate’s mines region of Brazil and even of the World. In Soledade town, there are the most important gemstone processing and trade companies of this State. Despite the abundance of gem materials, most of the objects produced in the different companies are very similar and have in common that they seldom are manufactured using new technological processes. Agate is usually exported as raw material or as cut polished slabs which can be dyed in various colors. Among several companies studied in this research, only one uses industrial processes involving new technologies. So, scientifical studies to indicate a better use of agate produced in Rio Grande do Sul, can provide new opportunities for the production of objects and personal ornaments (jewelry), modifying the trade where innovative designs are little explored. The methodology used in this study had several steps: identification of the extraction, processing and trade places of agate; evaluation of the industrial benefit processes used in agate; testing of conventional CNC machining on agate slabs; and testing on agate slabs of non-conventional computer controled machining by water jet cutting (WJC), with development of complex forms agate products. Twenty-four machining tests were carried out, with further analysis identifying ideal widths and thicknesses to optimize the use of agate raw material. With these tests, it was possible to achieve the goal of this study, which is to cut agate using water jet technology, in order to produce agate objects with complex forms.

No estado do Rio Grande do Sul, estão localizadas importantes regiões de extração e processamento do material gemológico ágata. No Distrito Mineiro do Salto do Jacuí encontram-se as maiores jazidas de ágata do Brasil e do Mundo. No município de Soledade se concentram as principais empresas de beneficiamento e comércio de materiais gemológicos. Apesar da abundância de material, a maioria dos objetos produzidos apresenta baixo grau de inovação, os produtos oferecidos no mercado são muito semelhantes entre si e tem, em comum, a falta de diferencial e de utilização de processos que envolvam tecnologia. A ágata é geralmente exportada em estado bruto ou apresentando baixo grau de aproveitamento. O processamento mais comum, utilizado na maior parte das empresas, é o corte em chapas que posteriormente são lixadas, polidas e tingidas em diversas cores. Entre as empresas pesquisadas no presente estudo apenas uma já utiliza processos envolvendo novas tecnologias. Pode-se afirmar que a pesquisa e estudos que auxiliem em um melhor aproveitamento do material ágata possam representar novas oportunidades de produção de objetos e adornos pessoais (jóias) modificando um cenário onde o design inovador é pouco explorado e apresentado. A metodologia empregada para a realização deste estudo contemplou etapas de conhecimento da realidade dos locais de extração, beneficiamento e comercialização de ágata, avaliação dos processos, ensaio de usinagem convencional CNC, ensaios de usinagem não convencional por jato d’água CNC e desenvolvimento de produtos em formas complexas. Foram realizados vinte e quatro ensaios de usinagem, a análise posterior identifica larguras e espessuras ideais buscando a otimização da matéria-prima. Desta forma foi possível alcançar o objetivo principal nesta pesquisa de realizar o corte de ágata com utilização de tecnologia CNC em peças com formas complexas. / Rio Grande do Sul State, Brazil, has important regions of extraction and processing of agate. Salto Jacuí Mining District, in the central region of this State, is one of the largest and more importante agate’s mines region of Brazil and even of the World. In Soledade town, there are the most important gemstone processing and trade companies of this State. Despite the abundance of gem materials, most of the objects produced in the different companies are very similar and have in common that they seldom are manufactured using new technological processes. Agate is usually exported as raw material or as cut polished slabs which can be dyed in various colors. Among several companies studied in this research, only one uses industrial processes involving new technologies. So, scientifical studies to indicate a better use of agate produced in Rio Grande do Sul, can provide new opportunities for the production of objects and personal ornaments (jewelry), modifying the trade where innovative designs are little explored. The methodology used in this study had several steps: identification of the extraction, processing and trade places of agate; evaluation of the industrial benefit processes used in agate; testing of conventional CNC machining on agate slabs; and testing on agate slabs of non-conventional computer controled machining by water jet cutting (WJC), with development of complex forms agate products. Twenty-four machining tests were carried out, with further analysis identifying ideal widths and thicknesses to optimize the use of agate raw material. With these tests, it was possible to achieve the goal of this study, which is to cut agate using water jet technology, in order to produce agate objects with complex forms.

No estado do Rio Grande do Sul, estão localizadas importantes regiões de extração e processamento do material gemológico ágata. No Distrito Mineiro do Salto do Jacuí encontram-se as maiores jazidas de ágata do Brasil e do Mundo. No município de Soledade se concentram as principais empresas de beneficiamento e comércio de materiais gemológicos. Apesar da abundância de material, a maioria dos objetos produzidos apresenta baixo grau de inovação, os produtos oferecidos no mercado são muito semelhantes entre si e tem, em comum, a falta de diferencial e de utilização de processos que envolvam tecnologia. A ágata é geralmente exportada em estado bruto ou apresentando baixo grau de aproveitamento. O processamento mais comum, utilizado na maior parte das empresas, é o corte em chapas que posteriormente são lixadas, polidas e tingidas em diversas cores. Entre as empresas pesquisadas no presente estudo apenas uma já utiliza processos envolvendo novas tecnologias. Pode-se afirmar que a pesquisa e estudos que auxiliem em um melhor aproveitamento do material ágata possam representar novas oportunidades de produção de objetos e adornos pessoais (jóias) modificando um cenário onde o design inovador é pouco explorado e apresentado. A metodologia empregada para a realização deste estudo contemplou etapas de conhecimento da realidade dos locais de extração, beneficiamento e comercialização de ágata, avaliação dos processos, ensaio de usinagem convencional CNC, ensaios de usinagem não convencional por jato d’água CNC e desenvolvimento de produtos em formas complexas. Foram realizados vinte e quatro ensaios de usinagem, a análise posterior identifica larguras e espessuras ideais buscando a otimização da matéria-prima. Desta forma foi possível alcançar o objetivo principal nesta pesquisa de realizar o corte de ágata com utilização de tecnologia CNC em peças com formas complexas. / Rio Grande do Sul State, Brazil, has important regions of extraction and processing of agate. Salto Jacuí Mining District, in the central region of this State, is one of the largest and more importante agate’s mines region of Brazil and even of the World. In Soledade town, there are the most important gemstone processing and trade companies of this State. Despite the abundance of gem materials, most of the objects produced in the different companies are very similar and have in common that they seldom are manufactured using new technological processes. Agate is usually exported as raw material or as cut polished slabs which can be dyed in various colors. Among several companies studied in this research, only one uses industrial processes involving new technologies. So, scientifical studies to indicate a better use of agate produced in Rio Grande do Sul, can provide new opportunities for the production of objects and personal ornaments (jewelry), modifying the trade where innovative designs are little explored. The methodology used in this study had several steps: identification of the extraction, processing and trade places of agate; evaluation of the industrial benefit processes used in agate; testing of conventional CNC machining on agate slabs; and testing on agate slabs of non-conventional computer controled machining by water jet cutting (WJC), with development of complex forms agate products. Twenty-four machining tests were carried out, with further analysis identifying ideal widths and thicknesses to optimize the use of agate raw material. With these tests, it was possible to achieve the goal of this study, which is to cut agate using water jet technology, in order to produce agate objects with complex forms.