Metal Cutting Simulation Finite Element Solution

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The cutting machining simulation technology is to study the physical phenomena in the analytical machining process. Through numerical simulation, the cutting force, strain, strain rate, chip, tool temperature and other values ​​are obtained. The DOE study and tool wear of cutting parameters and tools are studied. , and optimize the NC program based on simulation values ​​such as cutting force and temperature. Third Wave Systems, established in 1993, is responsible for the development and sale of finite element cutting simulation software, which responds to this demand in the processing market. Its product AdvantEdgetm FEM uses finite element method to simulate the cutting process; another product, Production Moduletm, excels in process analysis and optimizes NC programs based on cutting force, temperature, and other simulation values. AdvantEdgetm FEM Software Principles and Features AdvantEdgetm FEM uses the finite element method for physical simulation of the cutting process. Inputs for the cutting conditions include: workpiece material properties, tool geometry, tool material properties, cutting speed, coolant parameters, tool vibration parameters, cutting Parameters and so on. After the software passes the finite element analysis, the physical properties such as cutting force, chip rolling, chip formation, chip breaking, heat flow, temperature distribution on the tool workpiece and chip, stress distribution, strain distribution, residual stress distribution, etc. are obtained during the cutting process. result. Figure 1 shows the cutting simulation and cutting force comparison for the three types of tools; Figure 2 shows the chip formation and temperature distribution for different cutting parameters.

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Fig.1a Simulation of three kinds of cutting tools

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Figure 1b Comparison of Cutting Forces of 3 Tools

AdvantEdgetm FEM has an extensive library of materials, including 120 workpiece materials from cast iron to titanium alloys, 100 tool materials from Carbide, diamond to high speed steel, TiN, TiC, Al2O3, TiAlN coating materials; for extensive process analysis , Such as turning, milling (including plunge milling), drilling, boring, broaching, coolant intrusion, injection, etc. The tool wear simulation mainly uses the Japanese Usui algorithm; at the same time, it has the DOE study of cutting speed, feed amount, rake angle, arc radius of the cutting edge; cutting speed, feed amount, and tool change DOE; has a rich post processing function. . Benefit Analysis In the design and development of the tool, the AdvantEdgetm FEM software can be used to study the coating, shape, and material of the tool and recommend cutting parameters for the tool. In the actual cutting process, the best cutting tool and cutting parameters can be selected on the basis of software analysis without copying the recommended cutting conditions provided by the tool factory. Through simulation analysis to improve the removal rate of the material, optimize the cutting force and temperature, chip formation, reduce the distortion of the workpiece in metal cutting, reduce the residual stress, improve the quality of parts and tool performance, reduce the number of tests and cost of on-site trial cuts. Simulation technology helps companies improve product quality, extend tool life, improve machining processes, and significantly reduce product manufacturing costs. Production Moduletm Software Principles and Features Production Moduletm software is a process analysis software. Through comprehensive analysis of the workpiece, tool, material data and NC program, the cutting force, temperature and other data can be obtained during the entire machining process. Then, by optimizing the feed and cutting speed in the NC program, the cutting force, temperature, and other parameters in the machining process are optimized. As shown in Figure 3.

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Fig. 2 Chip formation and temperature distribution for different cutting parameters

After optimizing the analysis with Production Moduletm, it is possible to improve the cutting force and temperature in the machining process, achieve load balancing, reduce vibration, and reduce the processing cycle. The optimized NC program can be directly processed. Benefits Analysis The databases in the Production Moduletm software are all obtained from trials or AdvantEdgetm analysis. Enter the workpiece, workpiece material properties, tool parameters, G code/APT code, and machine tool control file. After analyzing these parameters, you can obtain the cutting force, temperature, power, etc. during the entire machining process. Then, by automatically optimizing the CNC program function or optimizing the feed and cutting speed parameters, the cutting force, temperature, and processing cycle are optimized to increase production efficiency. Comparison of cutting force and machining cycle before and after NC program optimization is shown in Fig. 4.

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Fig. 3 Through the comprehensive analysis of the workpiece, the machining path and the NC program, the cutting force during the entire machining process is obtained

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Fig. 4 Comparison of cutting force and machining cycle before and after optimization of NC program (red is optimized, green is optimized)

Concluding remarks With the continuous development of numerical calculation technology, numerical simulation has been developed in the direction of multi-disciplines, and the application of digital simulation technology in various industries has also continued to develop in depth. The application of product cutting and machining simulation technology in tool design, aerospace and automotive industries Gradually deepen. In order to meet the needs of domestic enterprises for the application of finite element simulation technology for metal cutting and the introduction of foreign advanced technology, Tengyi Co., Ltd. has been acting as the agent of Third Wave Systems' metal cutting simulation software since 2006, and is committed to providing metal cutting for the domestic manufacturing industry. Simulation of finite element solutions.

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