Computer simulation of cutting tools

1. From 2-D to 3-D

2.Software manufactures

3.Simulation in action

4.Application of simulation

From 2-D to 3-D

• Earlier research into the mechanics of machining focused on shear- zone models (2-D cutting).

•During the last two decades, researchers have successfully developed finite element analysis (FEA) to the metal cutting process in three dimensions.

Software manufactures

•There are some manufactures: Ingersoll Cutting Tool Co., Third Wave Systems

Inc. and etc.

• The Ingersoll simulator is able to differentiate the effects of various friction factors on chip formation, as well as other process parameters.

•Third Wave’s simulator lets predict the effects of cutting on the tool’s edge and geometry at user-defined process parameters.

Simulation in action

• A drill insert serves as an example of the simulator’s effectiveness in optimizing tool design.

Chips cut from soft materials (<220 HB) tend to be stringy and difficult to break.

C-shaped chips cut by the new insert based on data collected during simulations.

Temperature distribution of 3-D orthogonal cutting simulation

Effective stress distribution of 3-D cutting simulation

Application of simulation

•Simulation can be used to model turning, up and down milling, sawing,

and broaching.

•Workpiece materials that can be modeled include assorted grades of aluminum steel, copper, and 316 stainless steel.

•Among the tool materials and coatings that can be simulated are carbides,

ceramics, ultrahard materials, cobalt- base alloys, HSS, TiN, TiCN, and Al2O3.

Conclusion

Simulation allows:

1.to add a scientific component to the metalcutting process;

2.to reduce development costs;

3.to reduce the time needed to bring a new product to the market.