Abstract
The resources of modern Finite Element Analysis (FEA) software provide engineers with powerful mechanisms that can be used to investigate numerous machining processes with satisfying results. Nevertheless, the success of a simulation, especially in three dimensions, relies heavily on the accuracy of the cutting tool models that are implemented in the analyses. With this in mind, the present paper presents an application developed via Computer-Aided Design (CAD) programming that enables the automated design of accurate cutting tool models that can be used in 3D turning simulations. The presented application was developed with the aid of the programming resources of a commercially available CAD system. Moreover, the parametric design methodology was employed in order to design the tools according to the appropriate standards. Concluding, a sample tool model was tested by performing a number of machining simulations based on typical cutting parameters. The yielded results were then compared to experimental values of the generated machining force components for validation. The findings of the study prove the functionality of the tool models since a high level of agreement occurred between the acquired numerical results and the experimental ones.
Highlights
Nowadays, investigations on machining processes can benefit from the implementation of two dimensional or three dimensional Finite Element (FE) modelling
Li et al [19] proposed the optimization method of critical parameters of solid end mills, based on 3D FE simulations, providing a design system for end mills. In light of these considerations, the present paper describes a Computer-Aided Design (CAD)-based application that can be used to generate CAD models of standardized turning inserts
The center hole is created according to the selected clamping system. This feature does not play an important role during the FE analysis, rather it is used for more accurate representation of the cutting tool in a CAD-based layout of the turning process that includes a tool-holder
Summary
Investigations on machining processes can benefit from the implementation of two dimensional or three dimensional Finite Element (FE) modelling. With the advent of more advanced Computer-Aided Design (CAD) systems, it is possible to utilize the Application Programming Interface (API) and the parametric modelling to develop macros, applets or even software tools that can support numerous engineering processes such as the design and manufacturing of machine components, the inspection of manufacturing quality, as well as the integration of CAD, Computer-Aided Manufacturing (CAM) and Computer-Aided Engineering (CAE). Tzivelekis et al [5] proposed a novel approach for automating both the design and manufacturing processes of impeller-type geometries For this reason, authors developed an application based on API programming of commercially available CAD/CAM software. Li et al [19] proposed the optimization method of critical parameters of solid end mills, based on 3D FE simulations, providing a design system for end mills In light of these considerations, the present paper describes a CAD-based application that can be used to generate CAD models of standardized turning inserts. A set of 3D simulations was carried out by utilizing the FEA software DEFORMTM-3D to verify the functionality of the generated models and investigate their performance
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