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Advanced Machining Toolpath for Low Distortion

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Technical Report,01 Sep 2016,31 Dec 2016

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Third Wave Systems, Inc. Eden Prairie United States

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Third Wave Systems TWS completed a project funded by the Aviation Development Directorate ADD to minimize distortion in an aluminum fatigue coupon machining process. To achieve the objective of this project, TWS utilized its Production Module NC toolpath optimization, AdvantEdge finite element modeling, and distortion modeling software packages. Efforts in Production Module consisted of setting up an analysis of cutting forces across the fatigue coupon toolpath and optimizing these forces to level cutting loads and reduce force spikes. AdvantEdge was utilized to perform detailed finite element simulations of the finish machining toolpath with a focus on understanding the depth and magnitude of machining induced stresses imparted in the workpiece surface. Efforts in the distortion modeling software focused on simulating final part distortion due to the initial bulk stress in the aluminum stock material. TWS performed experimental tests in house to measure the initial bulk stress profiles that were used in the distortion modeling simulations. The outcome of this project was delivery of an optimized NC toolpath that reflected the modeling efforts to minimize final part distortion.

Subject Categories:

  • Fabrication Metallurgy

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