International Conference

2ND International Conference on Innovations, Recent Trends and Challenges

in Mechatronics, Mechanical Engineering and New High-Tech Products
Development

MECAHITECH10
Bucharest, 23-24 September 2010

Integrated Design Solutions- CNC Manufacturing for Complex

Products
St. Ganatios 1, O. Dontu 2, D. Besnea 2, R. Ciobanu 2, I. Avarvarei 2
1
University West Macedonia TEI Kozani - Greece
2
University Politehnica Buchaerest, Faculty of Mechanical Engineering and Mechatronics
No.313 Splaiul Independentei, Sector 6, Bucharest, Romania
E-mail: octavdontu@yahoo.com, d_bes@yahoo.com

ABSTRACT
This paper presents a way to design parts with complex geometry and manufacturing
techniques on machining centers with at least three numerically controlled axes. Using 3D
Wireframe and Surface Design applications, we present steps to follow and conceiving
mode, modeling and manufacturing of an injection mold for a plastic bottle emphasizing the
constructive and design features.
INTRODUCTION
The need to machine complex surfaces led to the mergence of a new generation of
products able to execute parts with 3D geometry and processing techniques on machines
with at least three numerically controlled axes. This method was embraced by all
manufacturers, in all the fields and at all the levels, starting from prototype to mass
production and its well adapted to the specific needs of the manufacturing processes.
High technology is based on this type of processing, offering integrated solutions,
from the tool path definition, verification and easy update, surface machining to providing
solutions easy to learn and use. Surface processing completely covers the designmanufacturing cycle, providing functions for defining operations to be materialized by a
machine, defining the processing strategy, processing row-roughing, finishing operations,
unprocessed zone detection, or machining in vertical or horizontal planes, such as Zlevel
machining, shaping, defining areas of processing, visualization of processing program,
documentation generation, offering a freedom of choice for the working methods that suits
best the needs of manufacturers.[1]
GENERAL PRESENTATION
NC Manufacturing allows defining and managing NC programs dedicated to parts that
are to be processed, designed in 3D wireframe or solid, using techniques from 2.5 up to 5
axes of processing. Being an unique solution, having a post processor engine that allows the
product item to cover all the entire manufacturing process (APT source or CL file) to NC
data., offering the following main functions :common platform for 2.5 5 axis;, flexible
management of fabrication program, graphic interface based on
dialog boxes;
personalization features by f(x) formula, generation of data to a post processor and instant
access to documentation in HTML format. High level of associability of manufacturing
284

International Conference
2ND International Conference on Innovations, Recent Trends and Challenges
in Mechatronics, Mechanical Engineering and New High-Tech Products
Development

MECAHITECH10
Bucharest, 23-24 September 2010

program assuring the change of the design and fabrication layout starting from the
integration of modeling capacity [2][3]. Having the 3D wireframe support application and
Surface Design, the steps and designing mode are presented as well as modeling and
manufacturing of a injection molds for a 750ml bottle (figure 1), highlighting specific features
and functional design.

Fig. 1 The bottle design

Due to required design and functional features for the model (labeling, shape of the
outer walls, rounded corners, ribs), the injection mold was designed to close at a 45 (fig 2),
offering thus a good finishing for the product, but posing a challenge to design conditions, NC
code generation and manufacturing on a 3(4) axis machine.

Fig. 2 Model of the mold, upper half and lower half.

285

International Conference
2ND International Conference on Innovations, Recent Trends and Challenges
in Mechatronics, Mechanical Engineering and New High-Tech Products
Development

MECAHITECH10
Bucharest, 23-24 September 2010

The part modeled using Wireframe and Surface Design tools saved in Product will
represent a model for the next stage, NC Manufacturing, offering specific methods for
selecting the operation by opening a window , Part Operation, fig 3, and initializing a new
execution in the manufacturing process by adding a new entity. The dialog window allows
selection of the operational side of the machine tool type required for the operation (Machine
Editor dialog window) fig 4. defining key features and parameters that can be adjusted
(machine name, comments, NC parameters, tool change parameters, tool register, rotating
table characteristics, etc).

Fig. 3 Selecting Part Operation

Fig 4. Machine Editor

Manufacturing Program module allows defining technological operations according to

surface type and machining type (roughing, finishing) by defining following types of
operations (drilling, point to point, pocketing, facing, curve following, profile contouring,
roughing, sweeping, pencil, ZLevel, contour, spiral milling, isoparametric machining, multi
axis helix machining). From insert menu a series of complete operations may be defined,
activating Machining Operations, Axial Machining Operations submenu is opened which
allows defining the axial operations ( drilling, boring, threading)[4].
Semi-finishing operation or ZLevel specific for horizontal parallel planes,
perpendicular to a machine axis and to create these type of operations a series of
parameters must be defined : geometry of the manufacturing area, tools, advances values,
tools speed, tool path. (fig 5). The dialog window allows user to select the part, machining
areas and protection areas . Selecting the Strategy option manufacturing parameters may
be specified, such as tool path and depth of milling on a single pass. Using Replay command
the tool path may be analyzed, (fig 6), Analyze photo icon offers details regarding possible
errors[5][6][7].

286

International Conference
2ND International Conference on Innovations, Recent Trends and Challenges
in Mechatronics, Mechanical Engineering and New High-Tech Products
Development

MECAHITECH10
Bucharest, 23-24 September 2010

Fig 5 Z Level operation icons, general view

Fig. 6 Tool path simulation

The code associated with the programs is generated by activating Generate NC

Code Icon. By opening the active window (fig 7), in IN/OUT page Document CAT Process is
selected and file location for the output file is specified.
287

International Conference
2ND International Conference on Innovations, Recent Trends and Challenges
in Mechatronics, Mechanical Engineering and New High-Tech Products
Development

MECAHITECH10
Bucharest, 23-24 September 2010

Fig. 7 Generating NC code

Fig. 8 The bottle obtain and wall detail

In what concerns the cutting, CAD/CAM designing offers a series of advantages,

each element of the manufacturing process is displayed in a hierarchy tree easy to use
allowing a full control over simulated machining process. The obtained product , fig 8,
proving the viability of integrated solutions.
REFERENCES
[1]I.G.Ghionea, Computer Aided Design in CATIA V5.Theretical elements and applications,
Bren Publishing Hause, Bucharest, 2007
[2] D.Besnea, O.Dontu, Tehnologii de fabricatie asistate de calculator pentru executia unor
componente mecatronice, Editura Printech Bucuresti, 2008
[3] D.Popescu, L.Popa s.a., Indrumar CATIA V5R8, Editura Aius, Bucuresti, 2004
[4] L. Rece, Ghid si aplicatii informatice de proiectare functionala si tehnologica a formelor
pieselor in 3 D, Editura Matrix Rom, Bucuresti, 2005
[5] M.Zapciu, Fabricatia asistata de calculator, Editura POLITEHNICA Press, 2003
[6] M.Popovici, Modelarea virtuala 3D in constructia de masini, Editura Printech, Bucuresti 2005
[7] CATIA V5P3R12, Documentatie de firma, Dassault Systemes
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