Founded in 1993, Third Wave Systems, Inc., develops and markets finite element cutting simulation software that responds to this demand in the processing market. Its product AdvantEdgetm FEM uses a finite element method to simulate the machining process; another product, Production Moduletm, specializes in process analysis and optimizes NC programs based on simulation values ​​such as cutting force and temperature.
AdvantEdgetm FEM Software
- Principles and Features AdvantEdgetm FEM uses the finite element method for physical simulation of the cutting process. The input conditions for the cutting conditions include: workpiece material properties, tool geometry, tool material properties, cutting speed, coolant parameters, tool vibration parameters, cutting parameters, etc. Through the finite element analysis, the software obtains the physical properties such as cutting force, chip rolling, chip formation, chip breaking, heat flow, temperature distribution on the workpiece and chip, stress distribution, strain distribution and residual stress distribution during the cutting process. result. Figure 1 shows the cutting simulation and cutting force comparison of the three tools; Figure 2 shows the chip formation and temperature distribution of different cutting parameters.
Figure 1a 3 kinds of tool cutting simulation
AdvantEdgetm FEM has a wide library of materials, including 120 workpiece materials from cast iron to titanium alloy, 100 tool materials from Carbide, diamond to high speed steel, TiN, TiC, Al2O3, TiAlN coating materials; Such as turning, milling (including plunge milling), drilling, boring, broaching, etc., coolant intrusion, injection and other methods. The tool wear simulation mainly adopts Japan's Usui algorithm; at the same time, it has the cutting speed, feed rate, rake angle, cutting edge radius parameter DOE research; cutting speed, feed rate, transform tool DOE research; has rich post-processing function .
Figure 1b Comparison of cutting force of three kinds of tools
- Benefit Analysis In the design and development of tools, AdvantEdgetm FEM software can be used to study the coating, shape, and material of the tool, and to recommend cutting parameters for the tool. In the actual cutting process, the optimal cutting tool and cutting parameters can be selected based on the software analysis based on the recommended cutting conditions provided by the tool factory. Through simulation analysis, the material removal rate is improved, the cutting force and temperature, chip formation are optimized, the distortion of the workpiece in metal cutting is reduced, the residual stress is reduced, the part quality and tool performance are improved, and the number of trials and costs of the field trial cutting are reduced.
Simulation technology helps companies improve product quality, extend tool life, improve processing, and significantly reduce product manufacturing costs.
Production Moduletm software
- Principles and Features Production Moduletm software is a process analysis software. Through comprehensive analysis of workpieces, tools, material data and NC programs, data such as cutting force and temperature during the entire machining process can be obtained. Then, by optimizing the feed and cutting speed in the NC program, parameters such as cutting force and temperature during machining are optimized. As shown in Figure 3.
After optimization analysis by Production Moduletm, the cutting force and temperature during the machining process can be improved, the load balance can be realized, the vibration can be reduced, and the machining cycle can be reduced. The optimized NC program can be processed directly.
Figure 2 Chip formation and temperature distribution for different cutting parameters
- Benefit Analysis The databases in the Production Moduletm software were obtained through trial or AdvantEdgetm analysis. Input workpiece, workpiece material characteristics, tool parameters, G code/APT code, machine tool control file, and analyze these parameters to obtain cutting force, temperature, power and other results during the entire machining process. Then, by optimizing the CNC program function or optimizing the feed and cutting speed parameters, the cutting force, temperature and machining cycle are optimized to increase production efficiency. The comparison of cutting force and machining cycle before and after NC program optimization is shown in Figure 4.
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Conclusion
With the continuous development of numerical computing technology, numerical simulation has been developed in a multi-disciplinary direction. The application of digital simulation technology in various industries is also developing in depth. The application of product cutting simulation technology in tool design, aerospace and automotive industries is gradually increasing. In-depth.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, KONE has been representing the metal cutting simulation software of Third Wave Systems of the United States since 2006, and is committed to providing metal cutting for the domestic manufacturing industry. Simulation finite element solution.
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