Machining simulation and system integration combining FE analysis and cutting mechanics modelling

In this paper, the machining process to produce the right surface profile in machining low-rigidity parts is studied by considering moving dynamic cutting forces that statically and dynamically excite the tool and part reducing the validity of these packages’ output and leading to additional surface errors. The proposed approach is based on producing a simulation environment integrating a data model, an analytical force prediction model, a material removal model and an FE analysis commercial software package. This reported result focuses on the development of the simulation environment and the data model. The integrated environment provides a platform by which FE analysis commercial packages, ABAQUS, can exchange data with the proposed data model, force model and material removal model, to deliver new functionality for machining process simulation where there is force-induced part deflection. The data model includes complete mesh and analysis information for predicting part deflection and enables iterative data updating for multi-step simulation. The proposed simulation methodology has been experimentally validated.