AdvantEdge-6-workshop

Version 6 Third Wave AdvantEdge Workshop Manual Table of Contents EXAMPLE 1 ADVANTEDGE INTRODUCTION 1 Strategy 1 Project Setup 1 Submitting the Project 2 Viewing the Results 3 Deleting the Project 4 EXAMPLE 2 INCREASING PRODUCTIVITY 5 Objective 5 Strategy 5 Project Setup 6 Creating a Batch File 6 Stopping the Batch File 7 Viewing and Analyzing Results 8 Speed Comparison 12 EXAMPLE 3 TOOL EDGE PREPARATION COMPARISON 14 Objective 14 Strategy 14 Project Setup 14 Submit Simulation 16 Analyzing the Results 17 EXAMPLE 4 TOOL DEFLECTION 21 Strategy 21 Project Setup 21 View Tool Deflection Results 23 Tool Deflection Results Advanced Analysis 24 EXAMPLE 5 RESIDUAL STRESS ANALYSIS 26 Objective 26 Strategy 26 Simulation Setup 27 Results Analysis 28 EXAMPLE 6 BALL NOSE END MILL ANALYSIS 31 Objective 31 Strategy 31 Simulation Setup 31 Results Analysis 32 DOE for Tool Wear Optimization 34 EXAMPLE 7 TOOL MATERIAL COATING ANALYSIS 36 Objective 36 Strategy 36 Simulation Setup 36 Results Analysis 38 EXAMPLE 8 TOOL IMPORT ANALYSIS USING TOOLING FROM GRINDING MACHINE SOFTWARE 41 Objective 41 Strategy 41 Simulation Setup 41 Results Analysis 46 EXAMPLE 9 RAKE ANGLE EFFECT ANALYSIS 48 Objective 48 Strategy 48 Simulation Setup 48 Results Analysis 50 EXAMPLE 10 DRILLING ANALYSIS 54 Objective 54 Strategy 54 Simulation Setup 54 Project Setup 54 Submitting the Project 58 Viewing the Results 60 EXAMPLE 11 2D COOLANT MODELING 69 Objective 69 Strategy 69 Simulation Setup 69 Project Setup 69 Results 71 1 Example 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 Tecplot Project Setup 1 Open AdvantEdge by selecting Start Programs Third Wave AdvantEdge AdvantEdge 2 Click Project New 3 Enter Example for the project name 4 Select Turning for project type 5 Check 2D Simulation and click OK Workpiece 6 Select Workpiece Create Edit Standard Workpiece 7 Enter a workpiece height of 1 and a workpiece length of 3 and click OK 8 Select Workpiece Workpiece Material 9 From the Workpiece Material pulldown menu select Cast Iron 10 Select the J431 G3000 material and click OK Note 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 Tool 11 Click Tool Import Tool Tools 12 Select the tool from C ThirdWaveSystems Workshop AdvantEdge Example 1 Introduction Tool twt and click OK 13 Select Tool Tool Material 14 Select the Carbide Grade K material and click OK 2 Process Parameters 15 Select Process Process Parameters 16 Within the Turning Process Parameters window enter the process parameters shown below and then click OK Simulation Output Customization 17 Select Simulation Simulation Options and access the General Tab 18 Select Demonstration for the simulation mode and click OK 19 A Warning window will open click OK Note 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 Project 20 Select Project Save As 21 Name the project Example twp place in C ThirdWaveSystems Workshop AdvantEdge Example 1 Introduction and click Save 3 22 Select Simulation Submit Submit Current Job and then click OK 23 A Job Monitor window will appear showing progress Viewing the Results 24 Select Simulation Results 25 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 Tecplot Zooming 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 point 4 Quick Analysis Window 26 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 Project Before 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 5 Example 2 Increasing Productivity Objective You 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 3 Strategy Part 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 6 Cutting Condition and Project Setup Project Name IncrProd Tool 1 Process Type 2D Turning Workpiece Material Steel AISI 4340 Process Parameters Feed 0 2 mm rev Depth of Cut 1 0 mm Length of Cut 4 2 mm Cutting Speed 75 m min Initial Temperature 20 degrees C Tool Location C ThirdWaveSystems Workshop AdvantEdge Example 2 Increasing Productivity Project Setup Incr Prod Tool 1Incr Prod Tool 2Incr Prod Tool 3 Tool Name Tool 1 twtTool 2 twtTool 3 twt Simulation Options 1 Select Simulation Simulation Options 2 Choose Steady State Analysis and click OK 3 Save the current job as IncrProd Tool 1 twp in C ThirdWaveSystems Workshop AdvantEdge Example 2 Increasing Productivity Now 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 to C ThirdWaveSystems Workshop AdvantEdge Example 2 Increasing Productivity Tool 2 twt 5 Save the project as IncrProd Tool 2 twp To create the third project 6 Import the second tool file into the current project Use Tool 3 by browsing to C ThirdWaveSystems Workshop AdvantEdge Example 2 Increasing Productivity Tool 3 twt 7 Save the project as IncrProd Tool 3 twp Creating a Batch File Creating 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 7 8 After saving the three project files above select Simulation Batch Job Create Edit Batch File 9 Browse to C ThirdWaveSystems Workshop AdvantEdge Example 2 Increasing Productivity enter IncrProd bat as the file name and click Open 10 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 File Before 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 STOP Class Discussion Question At 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 8 Viewing and Analyzing Results Make sure that you have stopped all the projects currently running in the AdvantEdge Job Monitor Open the project at C ThirdWaveSystems Workshop AdvantEdge Example 2 Increasing Productivity Results Results IncrProd Tool 1 Results IncrProd Tool 1 twp and view the results in Tecplot Simulation Results 13 Select Tools AdvantEdge Quick Analysis 14 To view only the force plots select View Time History Only from the AdvantEdge Quick Analysis window 15 In the Time History tab of the AdvantEdge Quick Analysis window select Polynomial Fit to apply a 10th order polynomial fit to the data 16 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 9 17 To view only the contour plots select View Contour Only from the AdvantEdge Quick Analysis 18 Select the Contour tab and select the variables of interest 19 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 50 C to 550 C 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 contours 22 To compare multiple results in the AdvantEdge Quick Analysis window select Tools Multi Project Display 23 Select Contour Comparison then click OK 10 Input 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 twp 24 Click OK A confirmation window will appear click OK 25 Compare and present the three project contours using the following options in the Contour tab Select Contour Animation Measure Distance 26 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 twp 28 Click OK then wait for two frames of data to load and display 11 29 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 STOP Class Discussion Questions 2 Which tool shows the lowest cutting force 3 Now that we have determined the tool that yields the lowest cutting force how can we use these results to improve the cutting process 4 Once the MRR is increased what simulations should be run to ensure there are no adverse effects 12 Speed Comparison Now 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 twp 31 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 twp 13 Recommendations Switch tooling to Insert 1 Increase cutting speed Set up additional projects to improve feed speed conditions for new insert 14 Cutting Condition and Project Setup Process Type 3D Turning Nose Turning Workpiece Material Ti 6Al 4V Tool Material Carbide Process Parameters Feed 0 1 mm per revolution Depth of Cut 0 4 mm Length of Cut 3 mm Cutting Speed 230 m min Initial Temperature 20 degrees C Tool Location C ThirdWaveSystems Workshop AdvantEdge Example 3 Tool Edge Prep Example 3 Tool Edge Preparation Comparison Objective Your 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 Strategy This 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 conditions Project Setup Edge Prep 25Edge Prep 50 Tool Name Tool Edge Prep 25 stpTool Edge Prep 50 stp 15 1 Import the twenty five micron tool by selecting Tool Import Tool STEP Tool File and browsing to C ThirdWaveSystems Workshop AdvantEdge Example 3 Tool Edge Prep Tool Edge Prep 25 stp 2 In the window that appears click Check Orient Tool a 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 16 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 at C ThirdWaveSystems Workshop AdvantEdge Example 3 Tool Edge Prep 6 Repeat the process for the fifty micron tool C ThirdWaveSystems Workshop AdvantEdge Tool Edge Prep Tool Edge Prep 50 stp saving as EdgePrep 50 Submit Simulation Note The process of submitting a 3D simulation is slightly different than for 2D 7 Select Simulation Submit Submit Current Job 8 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 17 STOP Class Discussion Question 1 When comparing the two simulations what are we looking for in order to determine the best tooling Analyzing the Results 10 Open Tecplot from Start Program Files Third Wave AdvantEdge Tecplot 11 Using the Multi Projects Display function open and compare the force plots for the two simulations located at C ThirdWaveSystems Workshop AdvantEdge Example 3 Tool Edge Prep Results 18 12 Using the Multi Projects Display function open and compare the contour plots for the two simulations located at C ThirdWaveSystems Workshop AdvantEdge Example 3 Tool Edge Prep Results 13 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 button b We want to focus on the tool edge turn the Chip and Workpiece OFF by selecting them in Contour tab c 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 view d To Zoom click hold the Center Mouse Button while moving the mouse up or downTo Pan across the screen click hold the Right Mouse Button while moving the mouse 19 e To Reset the Temperature levels in the Tecplot window select Plot Contour Multi Coloring navigate to the Levels tab select the New Levels button and set the levels to those shown on right Note These simulations were run with steady state analysis selected The last zone Zone 32 here displays the calculated steady state results while the remaining zones 1 31 show the results for a specific instant in time The zone displayed can be changed by selecting the Animation button and using the or arrows 20 STOP Class Discussion Questions 2 Which tool shows lower cutting forces Temperature 3 How will the lower cutting forces and temperatures benefit your process 21 Example 4 Tool Deflection Strategy Learn to use the tool deflection feature in 3D milling This feature can be used to incorporate the influence of tool forces and tool geometry on tool deflection Project Setup Baseline Cutting Condition and Project Setup Project Name ToolDeflection 100mm Process Type 3D Milling Solid Tool Side Cutting Down Milling Workpiece Material Al6061 T6 Default Tool Material Carbide Default Process Paramet