• To streamline process design so as to mini.
▪ Bottomline : To reduce manufacturing cycle time thereby achieving productivity improvement and cost savings.
********************
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
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.
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
MMataetreirailaltotobebe removed removed
Beam #1
Material Removal Simulation Flowchart
CAD/CAM System
FE Model (FEA Input Data)
NC/CAD DATA (Cutter Path- apt,
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
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.
▪ Assumption
▪ Apriori residual stresses in depth of work-piece influence resulting distortions more than surface residual stresses introduced by cutting process.
PT
1
PPRINT****************************************
********************
PPRINT LOAD 2" DIA FACE MILL WITH .312 CORNER
RADIUS
PPRINT****************************************
PT
3
FEDRAT/ 150.0000
GOTO / -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
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
▪ Companies that have been using Approach
▪ Boeing, UTC (Sikorsky), Embraer, Picheney
▪ Product
▪ Solver - MSC.Marc 2005 ▪ GUI - MSC.Marc Mentat 2005
Material Removal Simulation