Application of Advanced Skills of Highly-Skilled Workers to High-precision Deep Hole Drilling of Aluminum Alloy Die-casting Die

Abstract

The deep hole processing of the high die steel is important technique for manufacturing the die for aluminum die casting for alternative vehicles. The automatic deep hole processing for small diameter is difficult. The control parameters are important for the automatic deep hole processing because the inadequate parameters cause the drill breakage and the productivity decrease. Currently, the expert technicians having excellent skills manually carry out the deep hole processing to the die steel. If the automatic control parameters for the machining center can be obtained based on the skills of expert technicians, the automatic deep hole processing is become possible and the productivity improves. In this study, the appropriate feed speed and the appropriate cut depth in each step were investigated as the suitable control parameters based on the expert technician’s skills. The automatic deep hole processing tests were carried out with a machining center via the suitable control parameters. The product sample with many small deep holes was processed with the machining center via the suitable control parameters and the previous control parameters. The machining time via the suitable control parameters were 30 % lower than that of previous control parameters and the productivity improvement was achieved.