AdvantEdge-6-workshop.docx

Version 6Third Wave AdvantEdge Workshop ManualTable of ContentsEXAMPLE 1 - ADVANTEDGE INTRODUCTION1Strategy1Project Setup1Submitting the Project2Viewing the Results3Deleting the Project4EXAMPLE 2 - INCREASING PRODUCTIVITY5Objective5Strategy5Project Setup6Creating a Batch File6Stopping the Batch File7Viewing and Analyzing Results8Speed Comparison12EXAMPLE 3 - TOOL EDGE PREPARATION COMPARISON14Objective14Strategy14Project Setup14Submit Simulation16Analyzing the Results17EXAMPLE 4 - TOOL DEFLECTION21Strategy21Project Setup21View Tool Deflection Results23Tool Deflection Results Advanced Analysis24EXAMPLE 5 - RESIDUAL STRESS ANALYSIS26Objective26Strategy26Simulation Setup27Results Analysis28EXAMPLE 6 - BALL NOSE END MILL ANALYSIS31Objective31Strategy31Simulation Setup31Results Analysis32DOE for Tool Wear Optimization34EXAMPLE 7 - TOOL MATERIAL/COATING ANALYSIS36Objective36Strategy36Simulation Setup36Results Analysis38EXAMPLE 8 - TOOL IMPORT ANALYSIS USING TOOLING FROM GRINDING MACHINE SOFTWARE 41Objective41Strategy41Simulation Setup41Results Analysis46EXAMPLE 9 - RAKE ANGLE EFFECT ANALYSIS48Objective48Strategy48Simulation Setup48Results Analysis50EXAMPLE 10 - DRILLING ANALYSIS54Objective54Strategy54Simulation Setup54Project Setup54Submitting the Project58Viewing the Results60EXAMPLE 11 - 2D COOLANT MODELING69Objective69Strategy69Simulation Setup69Project Setup69Results71Example 1 - AdvantEdge Introduction Strategy Complete basic steps of setting up and submitting a new job. Learn to import a custom workpiece and tool. Learn how to analyze results using TecplotProject Setup1. Open AdvantEdge by selecting Start Programs Third Wave AdvantEdge AdvantEdge2. Click Project New3. Enter Example for the project name4. Select Turning for project type5. Check 2D Simulation and click OKWorkpiece6. Select Workpiece Create/Edit Standard Workpiece7. Enter a workpiece height of 1 and a workpiece length of 3, and click OK8. Select Workpiece Workpiece Material9. From the Workpiece Material pulldown menu, select Cast Iron10. Select the J431 G3000 material, and click OKNote the use of the Properties button for additional material information; the material hardness can be modified by selecting the User Define option in this window.Tool11. Click Tool Import Tool Tools12. Select the tool from C:ThirdWaveSystemsWorkshopAdvantEdgeExample_1- IntroductionTool.twt, and click OK13. Select Tool Tool Material14. Select the CarbideGrade-K material, and click OKProcess Parameters15. Select Process Process Parameters16. Within the Turning Process Parameters window, enter the process parameters shown below, and then click OKSimulation Output Customization17. Select Simulation Simulation Options and access the General Tab18. Select Demonstration for the simulation mode and click OK19. A Warning window will open, click OKNote: Demonstration mode is being used in this example to find a fast result for demonstration purposes. Generally, standard mode is recommended as it utilizes a more refined mesh to provide more reliable and accurate results.Submitting the Project20. Select Project Save As21. Name the project Example.twp, place inC:ThirdWaveSystemsWorkshopAdvantEdgeExample_1-Introduction, and click Save22. Select Simulation Submit Submit Current Job, and then click OK23. A Job Monitor window will appear showing progressViewing the Results24. Select Simulation Results25. Tecplot will now open and you will be able to view the results of the simulation thus far.Note: In order to see the most recent results, Tecplot must be closed and then re-opened. This will update the results to the point at which the simulation has currently run.Using TecplotZooming and Panning Click and hold the middle mouse button and zoom in and out by moving the mouse up and down. Pan around the results by clicking and dragging with the right mouse button.Probing for Data Click the Tool to Probe Data button from the Tecplot toolbar. Using the Probe tool, click on the simulation results to see information about that specific pointQuick Analysis Window26. The AdvantEdge Quick Analysis window should open automatically. If it does not, select Tools AdvantEdge Quick Analysis.27. Explore the different functions available in each of the different tabs. Contour relates to the top half of the results, and Time History relates to the bottom half.Deleting the ProjectBefore moving on, it is necessary to stop the job that is currently running (if it has not finished yet).28. Select Job Delete. The analysis will be stopped and removed from the AdvantEdge Job Monitor list.Example 2 - Increasing Productivity ObjectiveYou are a project engineer responsible for the delivery of machined components. You have just been informed that you need to increase production by 30% in the next two weeks. Your supervisor has decided that the best course of action is to see how two new tools compare in performance to the baseline tool. From there, you can begin to improve the process. Because of the time constraint, modeling proves to be an invaluable tool in improving the process. Using AdvantEdge, investigate several tooling options and process conditions in order to determine which tool will allow the greatest material removal rate (MRR).Tool 1Tool 2 (Baseline)Tool 3StrategyPart 1: Tool Comparison Set up and run 2D turning simulations to determine the cutting force for the baseline tool and the two new tools. Determine which tool shows the lowest cutting forces and temperatures.Part 2: Speed Increase Utilize reduced forces to increase cutting speed. Set up and run a simulation to determine if there are any adverse force or temperature effects.Cutting Condition and Project SetupProject Name:IncrProd_Tool_1Process Type:2D TurningWorkpiece Material:Steel AISI-4340Process Parameters:Feed:0.2 mm/revDepth of Cut:1.0 mmLength of Cut:4.2 mmCutting Speed:75 m/min Initial Temperature:20 degrees CTool Location:C:ThirdWaveSystemsWorkshopAdvantEdgeExample_2-Increasing_ProductivityProject SetupIncr_Prod_Tool_1Incr_Prod_Tool_2Incr_Prod_Tool_3Tool Name:Tool_1.twtTool_2.twtTool_3.twtSimulation Options1. Select Simulation Simulation Options2. Choose Steady-State Analysis, and click OK3. Save the current job as IncrProd_Tool_1.twp inC:ThirdWaveSystemsWorkshopAdvantEdgeExample_2-Increasing_ProductivityNow that we have finished setting up the project for the first tool, we must now set up projects for the other two tools. To create the second project:4. Import the second tool file into the current project. Use Tool 2 by browsing toC:ThirdWaveSystemsWorkshopAdvantEdgeExample_2-Increasing_ProductivityTool_2.twt5. Save the project as IncrProd_Tool_2.twpTo create the third project:6. Import the second tool file into the current project. Use Tool 3 by browsing toC:ThirdWaveSystemsWorkshopAdvantEdgeExample_2-Increasing_ProductivityTool_3.twt7. Save the project as IncrProd_Tool_3.twpCreating a Batch FileCreating a batch file allows you to set up several simulations and submit them together. When you start a batch file, the first simulation will begin and the next will automatically start after it concludes. Batch files allow you to run several simulations consecutively without having to submit each one separately.8. After saving the three project files above, select Simulation Batch Job Create/Edit Batch File9. Browse to C:ThirdWaveSystemsWorkshopAdvantEdgeExample_2-Increasing_Productivity, enter IncrProd.bat as the file name, and click Open10. In the lower window, Add the three name.inp files corresponding to the three project files you just created. The *.inp files are created automatically when the project files are saved. Each *.inp file must be added individually.11. Click OK. A DOS-based batch command line file will be created. If necessary, close the Create/Edit Batch Job window.12. Select Simulation Submit Submit Batch Job, browse to the batch file you just created, and click OK.Stopping the Batch FileBefore moving on to the next step, the batch files that you just started have to be stopped. There are two ways to stop the batch job. Select Job Stop from the AdvantEdge Job Monitor window and when the next job automatically starts, select Job Stop again. Repeat until all projects in the batch have been stopped.Note: Stopping a single project from the AdvantEdge Job Monitor does not stop the entire batch process. Close the DOS Window to stop the entire batch process.STOPClass DiscussionQuestionAt this point, the results simulations have been completed and the results have been created.1. With the goal of increasing MRR, what simulation data should we look at first?Viewing and Analyzing ResultsMake sure that you have stopped all the projects currently running in the AdvantEdge Job Monitor. Open the project at C:ThirdWaveSystemsWorkshopAdvantEdgeExample_2- Increasing_ProductivityResultsResults_IncrProd_Tool_1Results_IncrProd_Tool_1.twp and view the results in Tecplot (Simulation Results).13. Select Tools AdvantEdge Quick Analysis14. To view only the force plots, select View Time History Only from the AdvantEdge Quick Analysis window15. In the Time History tab of the AdvantEdge Quick Analysis window, select Polynomial Fit to apply a 10th order polynomial fit to the data16. Click the Probe tool button () on the Tecplot toolbar, then probe for cutting and feed force values at various positions. Right-click to go back to the Selector tool.17. To view only the contour plots, select View Contour Only from the AdvantEdge Quick Analysis18. Select the Contour tab and select the variables of interest19. In the Tecplot frame, select Plot Contour/Multi- Contour New Levels to change the contour scaling. This will allow you to better view the temperature gradient. For this example, a good range would be from 50C to 550C in 11 levels.20. In the Contour tab of the AdvantEdge Quick Analysis window, select Animation to step through individual frames.21. Using the Zoom tool and Probe tool , probe the tool tip for maximum values of different contours22. To compare multiple results in the AdvantEdge Quick Analysis window, select Tools Multi-Project Display23. Select Contour Comparison, then click OKInput 3 in the number of projects, then Browse to locate and select each project:Results_IncrProd_Tool_1.twp Results_IncrProd_Tool_2.twp Results_IncrProd_Tool_3.twp24. Click OK. A confirmation window will appear; click OK.25. Compare and present the three project contours using the following options in the Contourtab:Select Contour Animation Measure Distance26. Select Tools Multi-Project Display Force Comparison, and click OK.27. Using the Browse button, add the three project files individually:Results_IncrProd_Tool_1.twp Results_IncrProd_Tool_2.twp Results_IncrProd_Tool_3.twp28. Click OK, then wait for two frames of data to load and display29. The end result will resemble the following plot. Units can be converted, if necessary, by selecting Data SI to English or Data English to SI. Labels and text are added by using the text tool located on the Tecplot toolbar at the top.STOPClass DiscussionQuestions2. Which tool shows the lowest cutting force?3. Now that we have determined the tool that yields the lowest cutting force, how can we usethese results to improve the cutting process?4. Once the MRR is increased, what simulations should be run to ensure there are no adverseeffects?Speed ComparisonNow that we have determined which tool shows the lowest cutting force and temperature, set up and run a simulation for that tool with an increase in cutting speed from 75 m/min to 100 m/min.30. To compare the temperature contours of the new tool project at two different speeds with the baseline tool, repeat steps 22-25 with the following two files:Results_IncrProd_Tool_1.twp Results_IncrProd_Tool_1_100SMM.twp Results_IncrProd_Tool_2.twp31. To compare the cutting forces of the new tool project at two different speeds with the baseline tool, repeat steps 26-28 with the following two files:Results_IncrProd_Tool_1.twp Results_IncrProd_Tool_1_100SMM.twp Results_IncrProd_Tool_2.twpRecommendations Switch tooling to Insert #1 Increase cutting speed Set up additional projects to improve feed/speed conditions for new insert.Example 3 - Tool Edge Preparation Comparison ObjectiveYour company is looking into different tooling options for one of your turning processes. You have been given two identical Sandvik inserts differing only in the edge preparation. Your job is to decide between the two different edge preparations and determine which tooling is best for your process.StrategyThis example will allow you to explore the various functions of the Third Wave STEP Analyzer as well as learn how to approach a tooling comparison problem. Set up simulations with the specified cutting conditions Import the two different tools into the simulations Orient the tools using the STEP Analyzer Mesh and start running the simulations Load results for two previously run cases and compare force and temperature results Determine which tool is best suited for the cutting conditionsCutting Condition and Project SetupProcess Type:3D Turning Nose TurningWorkpiece Material:Ti-6Al-4VTool Material:CarbideProcess Parameters:Feed:0.1 mm per revolutionDepth of Cut:0.4 mmLength of Cut:3 mmCutting Speed:230 m/min Initial Temperature:20 degrees CTool Location:C:ThirdWaveSystemsWorkshopAdvantEdgeExample_3-Tool_Edge_PrepProject SetupEdge_Prep_25Edge_Prep_50Tool Name:Tool_Edge_Prep_25.stpTool_Edge_Prep_50.stp1. Import the twenty-five micron tool by selecting Tool Import Tool STEP Tool File and browsing to C:ThirdWaveSystemsWorkshopAdvantEdgeExample_3- Tool_Edge_PrepTool_Edge_Prep_25.stp2. In the window that appears, click Check/Orient Toola. Any faces that may not mesh properly will appear in a message box. If there are faces that will cause the mesher to fail, a warning box will appear and suggestions will be given to fix the problem. Click Continue. The STEP Analyzer will open.3. Within the STEP Analyzer, click the Check Orientation tab and orient the tool using the coordinates shown above.a. The X, Y, and Z coordinates define the tail of the vector, and the I, J, and K coordinates define the direction of the vector. Clicking Rotate will rotate the tool around the vector using the specified angle.Note: The location of the tool with respect to the axis does not matter, only the orientation.4. Click the Mesh Refinement tab of the STEP Analyzer and click the Face Selection button. Select the cutting edge by holding Shift + Left-Click for each of three faces shown at right.a. Click Edit Selection and set the Element Size to 0.0105 mm for the three faces, and then click Add.b. Click OK to close the STEP Analyzer.5. Save this setup as EdgePrep_25 atC:ThirdWaveSystemsWorkshopAdvantEdgeExample_3-Tool_Edge_Prep6. Repeat the process for the fifty micron tool, C:ThirdWaveSystemsWorkshopAdvantEdgeTool_Edge_PrepTool_Edge_Prep_50.stp, saving as EdgePrep_50.Submit SimulationNote: The process of submitting a 3D simulation is slightly different than for 2D.7. Select Simulation Submit Submit Current Job8. The simulation will now begin to mesh and a batch file will be created. When the meshing is complete, three options become available. Click View Mesh to view the initial mesh for the tool and workpiece.9. Click Submit Later to close the window with the option of returning to run the batch file at a later time.Note: You would click Submit Now to start running the simulation immediately; however, the results for this example have already been generated.STOPClass DiscussionQuestion1. When comparing the two simulations, what are we looking for in order to determine the best tooling?Analyzing the Results10. Open Tecplot from Start Program Files Third Wave AdvantEdge Tecplot11. Using the Multi-Projects Display function, open and compare the force plots for the two simulations, located at C:ThirdWaveSystemsWorkshopAdvantEdgeExample_3- Tool_Edge_PrepResults12. Using the Multi-Projects Display function, open and compare the contour plots for the two simulations, located at C:ThirdWaveSystemsWorkshopAdvantEdgeExample_3- Tool_Edge_PrepResults13. Examine the Temperature contours at the cutting edge:a. First, turn the Mesh OFF by navigating to the Contour tab in the AdvantEdge Quick Analysis window and clicking the Mesh buttonb. We want to focus on the tool edge, turn the Chip and Workpiece OFF by selecting them in Contour tabc. To rotate the view, select the Rollerball Rotation button on the Toolbar at top of Tecplot window and click-hold the Left Mouse Button while moving mouse. Pressing “o” on the keyboard with Rollerball Tool selected will reset the origin to current viewd. To Zoom click-h