Combining finite elements (FE) simulation and design of experiments (DoE) for an efficient saw tooth design process

Abstract

Tool manufacturers are facing increasing competitive pressure and growing demand for innovation. One key aspect in the tool manufacturing industry concerns the optimization of the design process of cutting tool geometries, which are essential for the efficiency and stability of the cutting process. Current approaches are experience based and require a large number of experimental cutting tests.This paper presents a novel approach for the optimization of the design process of circular saw teeth by combining FE simulation with DoE allowing a more sparing use of resources. Subsequently, the optimized circular saw tooth geometry is ground and validated by comparing the cutting forces resulting from the FE simulation with those measured during the experimental cutting tests.The results show a strong correlation between resulting cutting forces of the FE simulation when compared to those of experimental cutting tests, which drastically reduces the experimental effort, which in turn minimizes the number of test tools. Furthermore, it was shown that using the optimized saw tooth geometry, cutting forces were significantly reduced when compared to those of a standard tool geometry. This approach enables tool manufacturers to a more efficient and sustainable saw tooth design process, increasing their competitiveness in the machining industry.