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MMataetreirailaltotobebe removed removed
Beam #1
Material Removal Simulation Flowchart
CAD/CAM System
FE Model (FEA Input Data)
NC/CAD DATA (Cutter Path- apt,
• To streamline process design so as to minimize part fit-up issues.
▪ Bottomline : To reduce manufacturing cycle time thereby achieving productivity improvement and cost savings.
PT
1
PPRINT****************************************
********************
PPRINT LOAD 2" DIA FACE MILL WITH .312 CORNER
RADIUS
PPRINT****************************************
▪ Assumption
▪ Apriori residual stresses in depth of work-piece influence resulting distortions more than surface residual stresses introduced by cutting process.
cl files)
FEA Solver (MSC.Marc)
Initial Stress
FEA Results (Post-processing)
Solution Procedure
1. NC Data Interface 2. Initial Residual Stress Input 2. FE Solution 3. Visualization
MSC.Marc version 2005 Training MACHINING
Sheng Ping Wang MSC.Marc Development
FEM Simulation of NC Machining Processes
Objectives
• To predict the effects of insitu residual stress redistribution due to complex 3D machining of bulk components.
PT
3
FEDRAT/ 150.0000
GOT百度文库 / -2.00000, 19.00000, 13.30000
PT
4
GOTO /
.00000, 19.00000, 13.30000
PT
5
APT Source Data
CUTTER/ 2.0,.3120,.6880,.3120,.0,.0,4.0 FEDRAT/ 50.0 GOTO/ 20.0,20.0,20.0 PPRINT*************************************** ********************* PPRINT LOAD 2" DIA FACE MILL WITH .312 CORNER RADIUS PPRINT*************************************** ********************* LOADTL/ 230002.0,LENGTH,.0,OSETNO,1.0 SPINDL/ 9963.0,CLW COOLNT/ FLOOD RAPID GOTO/ -2.0,19.0,20.0 RAPID GOTO/ -2.0,19.0,14.0 FEDRAT/ 150.0 GOTO/ -2.0,19.0,13.30 GOTO/ .0,19.0,13.30 FEDRAT/ 105.0 GOTO/ 28.0,19.0,13.30 FEDRAT/ 150.0 GOTO/ 28.0,17.60,13.30
NC / CAD Data
CUTTER/
2.000000, .312000, .688000, .312000, .
000000,$
.000000, 4.000000
TLAXIS/ .000000, .000000, 1.000000
FEDRAT/ 50.0000
GOTO / 20.00000, 20.00000, 20.00000
CL Data
NC Data Interface
1. Cutter Geometry Identification
▪ Cutter statement: CUTTER/d,r,e,f,a,b,h
b e
h r f a d
Different Cutter Shapes
FEM Simulation of NC Machining Processes
▪ Approach
▪ Pseudo-simulation of machining process through automated material removal using NC cutting files (apt or cl files) as input.
▪ Companies that have been using Approach
▪ Boeing, UTC (Sikorsky), Embraer, Picheney
▪ Product
▪ Solver - MSC.Marc 2005 ▪ GUI - MSC.Marc Mentat 2005
Material Removal Simulation
********************
LOADTL/230002,LENGTH,0,OSETNO,1
SPINDL/9963,CLW
COOLNT/FLOOD
RAPID
GOTO / -2.00000, 19.00000, 20.00000
PT
2
RAPID
GOTO / -2.00000, 19.00000, 14.00000
Beam #1
Material Removal Simulation Flowchart
CAD/CAM System
FE Model (FEA Input Data)
NC/CAD DATA (Cutter Path- apt,
• To streamline process design so as to minimize part fit-up issues.
▪ Bottomline : To reduce manufacturing cycle time thereby achieving productivity improvement and cost savings.
PT
1
PPRINT****************************************
********************
PPRINT LOAD 2" DIA FACE MILL WITH .312 CORNER
RADIUS
PPRINT****************************************
▪ Assumption
▪ Apriori residual stresses in depth of work-piece influence resulting distortions more than surface residual stresses introduced by cutting process.
cl files)
FEA Solver (MSC.Marc)
Initial Stress
FEA Results (Post-processing)
Solution Procedure
1. NC Data Interface 2. Initial Residual Stress Input 2. FE Solution 3. Visualization
MSC.Marc version 2005 Training MACHINING
Sheng Ping Wang MSC.Marc Development
FEM Simulation of NC Machining Processes
Objectives
• To predict the effects of insitu residual stress redistribution due to complex 3D machining of bulk components.
PT
3
FEDRAT/ 150.0000
GOT百度文库 / -2.00000, 19.00000, 13.30000
PT
4
GOTO /
.00000, 19.00000, 13.30000
PT
5
APT Source Data
CUTTER/ 2.0,.3120,.6880,.3120,.0,.0,4.0 FEDRAT/ 50.0 GOTO/ 20.0,20.0,20.0 PPRINT*************************************** ********************* PPRINT LOAD 2" DIA FACE MILL WITH .312 CORNER RADIUS PPRINT*************************************** ********************* LOADTL/ 230002.0,LENGTH,.0,OSETNO,1.0 SPINDL/ 9963.0,CLW COOLNT/ FLOOD RAPID GOTO/ -2.0,19.0,20.0 RAPID GOTO/ -2.0,19.0,14.0 FEDRAT/ 150.0 GOTO/ -2.0,19.0,13.30 GOTO/ .0,19.0,13.30 FEDRAT/ 105.0 GOTO/ 28.0,19.0,13.30 FEDRAT/ 150.0 GOTO/ 28.0,17.60,13.30
NC / CAD Data
CUTTER/
2.000000, .312000, .688000, .312000, .
000000,$
.000000, 4.000000
TLAXIS/ .000000, .000000, 1.000000
FEDRAT/ 50.0000
GOTO / 20.00000, 20.00000, 20.00000
CL Data
NC Data Interface
1. Cutter Geometry Identification
▪ Cutter statement: CUTTER/d,r,e,f,a,b,h
b e
h r f a d
Different Cutter Shapes
FEM Simulation of NC Machining Processes
▪ Approach
▪ Pseudo-simulation of machining process through automated material removal using NC cutting files (apt or cl files) as input.
▪ Companies that have been using Approach
▪ Boeing, UTC (Sikorsky), Embraer, Picheney
▪ Product
▪ Solver - MSC.Marc 2005 ▪ GUI - MSC.Marc Mentat 2005
Material Removal Simulation
********************
LOADTL/230002,LENGTH,0,OSETNO,1
SPINDL/9963,CLW
COOLNT/FLOOD
RAPID
GOTO / -2.00000, 19.00000, 20.00000
PT
2
RAPID
GOTO / -2.00000, 19.00000, 14.00000