WHAT IS MACHINING/CUTTING SIMULATION WITH CAE? – BENEFITS & CASE STUDIES

By utilizing CAE (Computer Aided Engineering) in Metal Machining/Cutting, you can predict the shape of iron chips and the cutting force needed to form the metals with the appropriate tools and conditions. This means you can improve the cutting tool life. In this article, we will introduce an overview of “Machining,” the benefits of CAE analysis, and case studies.

WHAT IS MACHINING/CUTTING?

Machining/Cutting is a method of forming metals into the desired shapes by getting rid of the unnecessary parts of the metal as chips with a tool (cutting tool). This tool must be harder than the workpiece.

The biggest advantage of Machining/Cutting is that you can materialize the shapes that other forming methods cannot. The precision and quality of the shapes have been improving due to improvements in machines and tools. Since dies are not needed, it is also easy to handle a small quantity of products within a short delivery time.

The disadvantage of Machining is that this forming process produces scraps, which impact costs, and that it has lower productivity compared to other plastic forming processes such as pressing.

There are two types of Machining/Cutting:

• Rotary Machining/Cutting: Machining and boring with a cutting tool, punching, piercing, and tapping with a drill (drilling), gear hobbing, milling, and grinding with a grinding wheel
• Linear Machining/Cutting: Broaching, and gear shaping

BENEFITS OF CAE ANALYSIS FOR MACHINING/CUTTING

CAE analysis for Machining/Cutting enables you to predict the shapes of scraps and machining/cutting force during the process. So, you can expand tool life and form metals at a lower cost.

You can also predict changes in shapes that hold residual stress from other pre-forming processes after the machining/cutting process. So that you can form metals in inappropriate machining/cutting processes, avoid deformation that may occur in the post-forming process, and reduce production costs.

EXAMPLES OF CUTTING/MACHINING SIMULATIONS WITH A CAE SOLUTION

Now, we will introduce you examples of simulations using the CAE software DEFORM.

OTHER CASE STUDIES (Click on the image to visit the 3D animation page)

These are the case studies of turning, milling, and a prediction of deformation after Machining/Cutting.

Depending on the types of forming processes, conditions, and materials, the shapes of chips vary. A residual stress can affect the deformation of a metal after the process is finished.

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  Simulation of Drilling with a Spade Drill The case study of the Drilling (with a Spade Drill) simulation. You can evaluate the condition of the tool loads.

   

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  Simulation of Milling with an end mill The case study of Milling (with an end mill) simulation. You can visualize temperature changes in the swarf and the metal.

   

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  Simulation of Drilling The case study of the Drilling simulation. You can see how scraps are produced in the process.

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  Simulation of Tapping The case study of Tapping simulation. You can see a phenomenon that cannot be seen easily during an experiment.

   

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  Simulation for cutting tool development You can use CAE analysis to develop cutting tools. To evaluate the chips’ shape, the chip breaker’s shape and cutting conditions were altered in this case.

   

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  Simulation of deform prediction after the cutting/machining process This simulation shows you when residual stress from the heat treatment has been released.

   

CONCLUSION

Thank you for reading. We hope you enjoyed this article.

By utilizing CAE, defects can be prevented in advance, and costs and lead times can be reduced.

In addition to the examples introduced here, the CAE software DEFORM has a wide range of functions to support designers, including other processes, data analysis, the design of an experiment module, and an optimization module.
Please feel free to contact us if you have any questions or concerns about product design and manufacturing.