Modeling and Virtual Simulation of Hard Surface Milling and Forming Process Using Advanced CAE Systems

Abstract

This paper presents the influence of modeling and simulation techniques for hard milling and forming. The aim of these simulations is the ability to optimize the manufacturing technologies even before the real production of its own tools, because their manufacturing process is very difficult in terms of production time, materials and other costs. The simulated results visualize roughing and finishing process of milling and generate tool-paths in CATIA V5. Simulation results of forming realized in PAM-Stamp 2G using a 3D model of the punch and the blank confirm the suitability of the proposed design of the forming tool. Finally, hard milling and forming simulations in CAE systems CATIA V5 and PAM-Stamp 2G were performed in order to determine and evaluation of suitability of the proposed shapes of the forming tool.

Computer Aided Design and Manufacturing Evaluation of Milling Cutter when High Speed Machining of Hardened Steels

“…These programs [11,18] are called postprocessors. Postprocessors transform general information directly from CLData [6,19] and the output is usable CNC program for the selected machine. Postprocessors are usually independent programs that operate independently out of CAD/CAM.…”

“…The first step is to import a CAD part, followed by the orientation of the model to the required position depending on the coordinates of the control system of the machine tool data (type of cutting tool, geometry), inserting data about process parameters (spindle speed n, feed f, depth of cut a p ), information about the cutting tool movement during the machining operation. After defining these parameters [5,6] CNC program generates CLData (Cutter Location Data) file, which must be translated by postprocessor. Postprocessor processing can also be done in CAM system, if it is allowed by CNC system or its particular version.…”

“…The usage of CAD/CAM is considered to be the most effective solution for the implementation of technological preparation of production of complex shaped parts. In general, this sequence of creation of CNC programs is realized by the following steps [4,6,17]. The first step is to import a CAD part, followed by the orientation of the model to the required position depending on the coordinates of the control system of the machine tool data (type of cutting tool, geometry), inserting data about process parameters (spindle speed n, feed f, depth of cut a p ), information about the cutting tool movement during the machining operation.…”

“…These requirements can be effectively achieved only through the use of advanced information CAE (Computer Aided Engineering) technology to help us implement increasingly stringent demands on productivity and quality in the design and production [1,2]. According to the investigation of these authors [4,5,6,7], so-called CAE systems are used for implementation of the requirements in manufacturing practices, which are intended for the development and design of products, graphic modeling, structural analysis of the components, to the programming of production activities CAM (Computer Aided Manufacturing) [8,9] and CNC (Computer Numerical Control) systems. The development of innovative products and their realisation by means of advanced manufacturing methods and process combinations is a key issue in international competitiveness.…”

“…Accuracy and complete information about compressibility and other technological conditions influence the quality of final design. Authors used the technology of hard dry milling [3,4,6], to the manufacture of punch. In hard milling application are usually used coated [3] monolithic end mills or milling cutters with changeable cutting inserts made of H type cemented carbide, or very hard cutting materials.…”