Machining Modeling

Machining Modeling to Drive Innovation

Trial-and-error testing and the linear thinking associated with it to improve machining processes has been in place for over 100 years. Test data has even been packaged in modeling software to enable this mindset. These methods appear to work fine, until you:

  • Break an extremely expensive tool
  • Destroy a machine tool spindle
  • Scrap an expensive workpiece due to an incorrect or misinformed decision
  • Need to rework a bad NC program (oftentimes with multiple revisions)
  • Lose business because of one or more of the above

Sound familiar? You’ve exceeded the limits of the linear world, the machine is down, and the plant manager is not happy. This approach can be frustrating, time consuming and extremely limiting.

Nonlinear methods are needed for Bold Innovation. Third Wave Systems’ products don’t ignore the nonlinearity of machining, instead, they tackle it head-on. We’ve worked hard to make sure our software meets the challenge of today’s machining environment on the cutting edge. TWS’ products are the only FEM-based, experimentally validated CAE products that analyze the material behavior at the tool cutting edge and at the toolpath level. They are easy to use because they are designed for people who understand machining, by people who understand it themselves. Here’s what you’ll find “under the hood” of these products:

  • Advanced constitutive material models for accurate machining modeling
  • Explicit-dynamic FEM solver to model complex mechanics
  • FEM-driven toolpath modeling to provide more than just cutting forces
  • Advanced algorithms to simplify analysis
  • Open architecture to enable end-to-end analysis automation

Advanced Constitutive Material Models

Material behavior under machining conditions is inherently nonlinear. For example, pressure on a cutting edge turning Inconel at 300 SFM or milling at 3000 SFM results from a complex interaction of thermal-softening and strain-hardening as the material is sheared. Cutting test output can be beneficial in certain situations but is severely limited in its predictions over a wide range of cutting conditions.

By comparison, Third Wave Systems’ advanced material models are based on fundamental material properties, capturing nonlinearity, which provides better predictions and consistent results. This is the best and only comprehensive way to understand machining processes.

Study tool stress at different sections of the model

Intelligent Adaptive Meshing

Explicit-Dynamic FEM solver

Third Wave Systems’ Explicit-Dynamic FEM solver contains the critical algorithms needed for machining modeling. Accurately modeling the machining process requires an understanding of the energy distribution at the workpiece-tool-chip interface that can be effectively analyzed only through a thermo-mechanically coupled system. The separation of the chip and its flow over the rake face requires solving the multi-body contact problem. Advanced adaptive meshing algorithms are needed to intelligently manage the extreme deformation in the cutting zone. In addition, the usage of High-Performance Computing (HPC) technology is critical to managing the various complexities in machining while providing reliable results as quickly as possible.

FEM-Driven Toolpath-Level Modeling

Third Wave Systems provides FEM driven toolpath level modeling technology that integrates physics-based material models, CAD/CAM data, tooling and workpiece geometries to analyze and optimize machining processes. It provides forces, temperature, linear pressure, to name some of the outputs used for machining analysis.  Optimizing a machining process is beyond just cycle time savings. Understanding the load on a spindle can help prevent unscheduled downtime. Having a detailed analysis of every degree of rotation can help improve part quality. Workholding design using the toolpath analysis can help shorten the New Product Introduction time.

Toolpath-Level Modeling Technology

Optimization in Production Module

Advanced Toolpath-Level Optimization Algorithms

Third Wave Systems has developed advanced statistical algorithms to help you optimize processes to reduce cycle times while maintaining or improving tool life. These suggested optimization values support faster new user onboarding while providing a standardized methodology across your organization.

Openness for Advanced Users

With around 150 materials in the database, Third Wave Systems’ technology simplifies the job of creating new material models, giving you the flexibility to boldly innovate with new modeling approaches. You can also test hypotheses and uncover new machining techniques that work for you.

Our API toolkit provides you the flexibility to automate the end-to-end process of analysis and optimization, and to integrate with your broader Industry 4.0 initiative. The API toolkit is the underlying foundation of the CAM interfaces. Interfaces with Siemens NX, CATIA and Mastercam enable toolpath analysis to be part of the toolpath creation workflow.

Temperature Validation for Advanced Constitutive Material Models

Get in touch with TWS!