CAD-Based Automated Design of FEA-Ready Cutting Tools
<p>Basic geometric parameters of the SNGA120412S01525 (<b>a</b>), the CNGA120408T01020 (<b>b</b>) and the DNGA150404S01020 (<b>c</b>) inserts, along with their common sectioned view (<b>d</b>).</p> "> Figure 2
<p>The micro-geometry of a typical 80° diamond-shaped insert.</p> "> Figure 3
<p>The application’s interface and the corresponding code keys.</p> "> Figure 4
<p>The application’s workflow.</p> "> Figure 5
<p>The design workflow for the CNGA-family inserts: (<b>a</b>) the construction circle, (<b>b</b>) the contour, (<b>c</b>) the extrusion, (<b>d</b>) the corner radius, (<b>e</b>) the micro-geometry and (<b>f</b>) the clamping hole.</p> "> Figure 6
<p>The shape selector algorithm flowchart.</p> "> Figure 7
<p>The test framework including: (<b>a</b>) the Finite Element (FE) model setup, (<b>b</b>) the force diagrams and (<b>c</b>) the results.</p> "> Figure 8
<p>The model setup (<b>a</b>), the analysis domain (<b>b</b>) and the meshed tool (<b>c</b>).</p> "> Figure 9
<p>Simulated versus experimental machining force components: (<b>a</b>) the radial force, (<b>b</b>) the tangential force, (<b>c</b>) the feed force and (<b>d</b>) the resultant machining force.</p> ">
Abstract
:1. Introduction
2. Materials and Methods
2.1. Description of Turning Inserts
2.2. Design of the User Interface
2.3. Modelling Procedure of Turning Cutting Tools
3. Results and Discussion
3.1. Testing of the Generated Cutting Tool Models
3.2. Comparison of the Obtained Results
4. Conclusions
- The generated cutting tool was successfully imported to DEFORM™-3D and meshed with the maximum available number of elements.
- All the performed simulations were successfully completed within a reasonable amount of time.
- The performance of the under study cutting tool model was high, since the yielded results for the machining forces were on par with the experimental ones.
- Finally, the simulated resultant of the machining forces was in high agreement with the experimental one exceeding 90% in most cases.
Author Contributions
Funding
Conflicts of Interest
References
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Method | Functionality | Return Value |
---|---|---|
ActiveDoc | Connects to the currently active document | Model document |
NewDocument | Creates a new document using the specified template | Newly created document |
InsertSketch | Inserts a new sketch in the current part or assembly document | − |
CreateCircleByRadius2 | Creates a circle based on a center point and a specified radius | Newly created circle |
CreateConstructionGeometry | Sets selected sketch segments to be construction geometry instead of sketch geometry | − |
AddDimension2 | Creates a display dimension at the specified location for selected entities | Newly created dimension |
CreateLine | Creates a sketch line in the currently active 2D or 3D sketch | Sketch segment for the line |
SketchAddConstraints | Adds the specified constraint to the selected entities | − |
FeatureExtrusion3 | Creates an extruded feature | IFeature |
Method | Functionality | Return Value |
---|---|---|
GetBodies2 | Gets the bodies in the active part | Array of bodies |
GetFaces | Gets all the faces on the body | Array of faces on the body |
GetEdges | Get the edges bounding the selected face | Array of edges |
SetEntityName | Sets the name of the entity | True/false |
GetEntityByName | Gets an entity (face, edge, vertex) by name | Entity |
Select4 | Selects an entity and marks it | True/false |
FeatureFillet3 | Creates a fillet feature for selected edges and control point references | IFeature |
InsertFeatureChamfer | Inserts a chamfer | Pointer to the IFeature object |
FeatureCut4 | Creates a cut extrude feature | Cut extrude feature |
SaveAs | Saves the active document to the specified name in the specified format | True/false |
Cutting Conditions | Fr [N] | Ft [N] | Fa [N] | ||||||
---|---|---|---|---|---|---|---|---|---|
Std Order | Vc [m/min] | f [mm/rev] | ap [mm] | Exp. | FE Model | Exp. | FE Model | Exp. | FE Model |
1 | 80 | 0.08 | 0.30 | 251.0 | 284.2 | 125.1 | 156.8 | 114.1 | 115.7 |
2 | 80 | 0.11 | 0.30 | 281.6 | 302.1 | 152.1 | 185.9 | 126.6 | 123.4 |
3 | 80 | 0.14 | 0.30 | 319.0 | 339.6 | 200.2 | 205.7 | 144.0 | 125.6 |
4 | 115 | 0.08 | 0.30 | 244.3 | 269.4 | 125.3 | 145.5 | 118.4 | 112.1 |
5 | 115 | 0.11 | 0.30 | 287.9 | 295.3 | 150.5 | 176.8 | 134.0 | 120.5 |
6 | 115 | 0.14 | 0.30 | 297.6 | 324.2 | 179.9 | 202.9 | 133.6 | 120.8 |
7 | 150 | 0.08 | 0.30 | 258.4 | 251.7 | 116.1 | 132.7 | 116.6 | 105.9 |
8 | 150 | 0.11 | 0.30 | 281.4 | 291.5 | 152.5 | 169.9 | 125.5 | 114.5 |
9 | 150 | 0.14 | 0.30 | 323.0 | 337.0 | 176.1 | 199.3 | 140.2 | 113.2 |
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Tzotzis, A.; García-Hernández, C.; Huertas-Talón, J.-L.; Kyratsis, P. CAD-Based Automated Design of FEA-Ready Cutting Tools. J. Manuf. Mater. Process. 2020, 4, 104. https://doi.org/10.3390/jmmp4040104
Tzotzis A, García-Hernández C, Huertas-Talón J-L, Kyratsis P. CAD-Based Automated Design of FEA-Ready Cutting Tools. Journal of Manufacturing and Materials Processing. 2020; 4(4):104. https://doi.org/10.3390/jmmp4040104
Chicago/Turabian StyleTzotzis, Anastasios, César García-Hernández, José-Luis Huertas-Talón, and Panagiotis Kyratsis. 2020. "CAD-Based Automated Design of FEA-Ready Cutting Tools" Journal of Manufacturing and Materials Processing 4, no. 4: 104. https://doi.org/10.3390/jmmp4040104