Seamless Die Repair Machining Using Pyramid Spherical Coordinates

Seamless Die Repair Machining Using Pyramid Spherical Coordinates | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Seamless Die Repair Machining Using Pyramid Spherical Coordinates Jianhui Fu, Hyeonmin Jeong, Yoongho Jung This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7835708/v1 This work is licensed under a CC BY 4.0 License Status: Under Revision Version 1 posted 5 You are reading this latest preprint version Abstract Local repair of deformed or worn dies typically involves welding and re-machining using the original numerical control (NC) data. However, this conventional approach often results in repair-machining-mismatch (RMM) marks at the interface between re-machined and unrepaired areas. Even sub-millimeter RMMs can cause visible surface defects on products, requiring additional finishing to fix these imperfections. We propose an RMM-preventive method for die repair machining based on mesh merging with pyramid spherical coordinates (PSC). The original surface is directly reconstructed from NC data to create the source mesh, and the source and target boundaries are specified using coordinate-measuring-machine data from the deformed die. Applying PSC establishes a one-to-one correspondence between boundaries, ensuring the geometric features of the original surface are maintained. Revised NC data are then generated, allowing the re-machined section to join seamlessly with the deformed die surface. Experimental validation on a 500 × 500 mm die with intentional deformation demonstrated that the proposed method reduced boundary RMMs by over 94%, with residual deviations of less than 0.03 mm. These results demonstrate that the approach offers a practical and effective solution for RMM-free die repair machining, eliminating the need for a nominal CAD model, and can also be extended to other types of dies and industrial parts. Die repair Boundary mismatch Automotive press dies Pyramid spherical coordinates NC data Full Text Supplementary Files PermissionfromSpringeronReference10Fig23.pdf Cite Share Download PDF Status: Under Revision Version 1 posted Editorial decision: Major Revisions Needed 19 Dec, 2025 Reviewers agreed at journal 30 Oct, 2025 Reviewers invited by journal 29 Oct, 2025 Editor assigned by journal 15 Oct, 2025 First submitted to journal 13 Oct, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7835708","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":536980787,"identity":"1e0b40ca-b0bf-4c65-91e8-42af8ee73a9a","order_by":0,"name":"Jianhui Fu","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Jianhui","middleName":"","lastName":"Fu","suffix":""},{"id":536980788,"identity":"fe0dd97a-da4d-4e97-a4fc-c8748394a79c","order_by":1,"name":"Hyeonmin 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Coordinates","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"Die repair, Boundary mismatch, Automotive press dies, Pyramid spherical coordinates, NC data","lastPublishedDoi":"10.21203/rs.3.rs-7835708/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-7835708/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eLocal repair of deformed or worn dies typically involves welding and re-machining using the original numerical control (NC) data. However, this conventional approach often results in repair-machining-mismatch (RMM) marks at the interface between re-machined and unrepaired areas. Even sub-millimeter RMMs can cause visible surface defects on products, requiring additional finishing to fix these imperfections. We propose an RMM-preventive method for die repair machining based on mesh merging with pyramid spherical coordinates (PSC). The original surface is directly reconstructed from NC data to create the source mesh, and the source and target boundaries are specified using coordinate-measuring-machine data from the deformed die. Applying PSC establishes a one-to-one correspondence between boundaries, ensuring the geometric features of the original surface are maintained. Revised NC data are then generated, allowing the re-machined section to join seamlessly with the deformed die surface. Experimental validation on a 500 \u0026times; 500 mm die with intentional deformation demonstrated that the proposed method reduced boundary RMMs by over 94%, with residual deviations of less than 0.03 mm. These results demonstrate that the approach offers a practical and effective solution for RMM-free die repair machining, eliminating the need for a nominal CAD model, and can also be extended to other types of dies and industrial parts.\u003c/p\u003e","manuscriptTitle":"Seamless Die Repair Machining Using Pyramid Spherical Coordinates","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-11-10 03:36:23","doi":"10.21203/rs.3.rs-7835708/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"decision","content":"Major Revisions Needed","date":"2025-12-19T10:11:56+00:00","index":"","fulltext":""},{"type":"reviewerAgreed","content":"","date":"2025-10-30T06:08:52+00:00","index":0,"fulltext":""},{"type":"reviewersInvited","content":"","date":"2025-10-29T14:53:01+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2025-10-15T22:36:02+00:00","index":"","fulltext":""},{"type":"submitted","content":"The International Journal of Advanced Manufacturing Technology","date":"2025-10-13T20:47:26+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"b57851ba-9301-43e2-8a39-2ea9d3a40a6a","owner":[],"postedDate":"November 10th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"in-revision","subjectAreas":[],"tags":[],"updatedAt":"2025-12-19T15:12:10+00:00","versionOfRecord":[],"versionCreatedAt":"2025-11-10 03:36:23","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-7835708","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-7835708","identity":"rs-7835708","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}