Investigation of the Effect of Workpiece Resolution on Milling Simulation Accuracy in Production Module 3D CAE Software

The aim of this work was to present the effect of workpiece resolution on simulation accuracy in Production Module 3D CAE software. The concept of resolution and working principle of CAD model conversion into proprietary *.TWSM format was explained. Next, the effects of model resolution on simulation results were presented, using an example of a face milling operation. Four different workpiece model resolutions were used, including the resolution value recommended by the software developer. Comparison of simulation results for different workpiece resolutions was conducted, obtained results were analysed, with particular focus on the effect of workpiece resolution on simulated cutting force values. The authors have found a substantial link between workpiece resolution, material removal rate and simulation accuracy

The effect of changes in depth of cut and cutting speed of CNC toolpaths on turning process performance

In this article, a novel approach to computer optimization of CNC toolpaths by adjustment of cutting speed vcand depth of cut apis presented. Available software works by the principle of adjusting feed rate on the basis of calculations and numerical simulation of the machining process. The authors wish to expand upon this approach by proposing toolpath optimization by altering two other basic process parameters. Intricacies and problems related totheadjustment of apand vcwere explained in the introductory part. Simulation of different variant of the same turning process with different parameter values were conducted to evaluate the effect of changes in depth of cut and cutting speed on process performance. Obtained results were investigated on the account of cutting force and tool life. The authors have found that depth of cut substantially affects cutting force, while the effect of cutting speed on it is minimal. An increase in both depth of cut and cutting speed affects tool life negatively, although the impact of cutting speed is much more severe. An increase in depth of cut allows for a more significant reduction of machining time, while affecting tool life less negatively. On the other hand, the adjustment of cutting speed helpsto reduce machining time without increasing cutting force component values and spindle load

Optimization of Johnson–Cook constitutive model parameters

In modern machining industry, the concept of process optimization has gained widespread recognition. FEM simulations are commonly used for the optimization of machining operations, allowing for a proper choice of tool geometry and process parameters to obtain results that are in accordance with end user criteria. However, one has to be wary that a good agreement of experimental and simulation results is mandatory if the simulation is to be used as a basis for optimization of a real-life process. Therefore, a proper choice of constitutive model parameters is vital. Those parameter values are dependent on many variables. Constitutive model parameter values are determined experimentally – therefore, they are accurate only for the conditions (temperature, strain rate etc.) under which the experiment was performed. The alteration, or optimization of model parameters is necessary if cutting and experiment conditions differ, if one wishes to obtain applicable results. In this work, the authors aim to present a method of optimizing the Johnson–Cook constitutive model parameters to obtain a better fit with experimental data