Research On Key Technologies Of The Platform Control System And Process Of Decomposed Injection Sculpturing

Decomposed Injection Sculpturing (DIS) combines the material discrete/additive process and Numerical Control (NC) machining. DIS possesses the characteristics of both the flexibility of RP and the high precision of NC machining. Several key problems are studied, which are mainly relevant to DIS process platform control system, the process properties of material and the simulation and optimization of injection process. The finished work is as follows:At first, in this paper, the mechanical structure and its working principle of the DIS process platform are studied, considering of the special need of DIS. It can be the foundation of the latter content, such as PLC and the adjustment of PID and so on. Then, a kind of manufactable wax was chosen as part material and a kind of water-soluble wax was taken as supporting material. The matching properties and the feasibility of the two wax were analyzed.Secondly, considering the characteristic of the DIS process, a basic constructural type of"PC+PMAC"is applied. The PC is in charge of the non real-time motion control, and the PMAC is in charge of real-time tasks. The technologies of the interface among motion contorller, servo unit and hydraulic control are studied. The debug of the whole system has been done by experimental tests. The motion control of the DIS process platform can be carried out clearly.Third, the processing properties of part material (Manufacturable wax) and support material (Water-soluble wax) were experimentally studied. The influences of injecting parameters, machining parameters and tool's geometric parameters on the roughness of machined surface of water-soluble wax part were carried out. The influences of injecting parameters on the warpage of manufacturable wax part were investigated.At last, the process of compacts was simulated and analyzed by the CAE software MPI (Moldflow Plastics Insight). The position and degree of injecting defect was predicted. A group of reasonable injecting parameters was recommended. By the comprehensive considering the results studied, a part was chosen to validate the DIS process and its result was very encouraging.