Physics-based CAE solutions for companies that machine

Production Module

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Production Module integrates physics-based material models, CAD/CAM data, tooling and workpiece geometries to analyze and optimize machining processes. The software allows users to analyze cutting forces for each line of toolpath, compare forces to optimization limits and raise/lower feeds to attain maximum allowable forces.

HOW THIRD WAVE SYSTEMS GETS YOUR PRODUCTS TO MARKET FASTER

CYCLE TIME SAVINGS » Balance forces across toolpath while maintaining tool life

» Optimize feedrates and speeds for time reduction

» Reduce air cutting time

TOOL COST REDUCTION » Reduce force spikes

» Extend tool life

» Avoid tool breakage

REDUCE PROGRAMMING EFFORT » Visualize cutting forces and peak tool temperature of untested toolpaths

» Specify baseline feedrates on initial setup

» Reduce trial-and-error of new toolpath programming

» Interfaces for Siemens NX, Mastercam and CATIA

» Adopt standard optimization approach across your organization

IMPROVE PART QUALITY » Minimize workpiece or tool deflection

» Reduce cutting forces to improve surface finish

» Balance forces to improve dimensional accuracy

HOW THIRD WAVE SYSTEMS IMPROVES YOUR PARTS & PROCESSES

Market leading NC optimization

» User defines or imports tool geometries, stock workpiece and selects material

» User imports toolpath and runs the analysis

» Production Module balances tool loads

• Analyzes each toolpath line, calculating forces, spindle power, temperature, tool stress, etc.

• Advanced algorithms suggest values to be used for optimization

• Compares calculated outputs to optimization limits

• Raises/lowers feedrates to attain optimal machining performance

HOW IT WORKS

INPUTS » Machine tool characteristics

» Cutting tool descriptions

» Workpiece material and geometry

» Toolpath

FEATURES » Library of 140+ workpiece material models

» STL/STEP workpiece and tool import

» MetalMAX™ data import

» VERICUT® setup import

» NX® interface

» CATIA® interface

» Mastercam® interface

PRODUCT SPECIFICATIONS

OUTPUTS » Optimized NC programs incorporating new feeds and speeds

» Process data including cutting forces, temperatures, spindle power, tool engagements, stability analysis, load-per-unit length, etc.

» Interactive plots highlighting the correlation between cutting loads and tool position within the toolpath

Load leveling opportunity to

reduce cycle time.

Force spikes identified based on workpeice

geometry, material, tool rake angles and helix

angles.

Feed rates optimized across toolpath.

Air-cut feed rates optimized

Tangential force value for optimization

suggested by advanced algorithms

A U.S. automotive manufacturer was looking to machine engine blocks more effectively and used Production Module to reduce overall machining time, improve tool life and avoid purchasing high-cost capital equipment.

Results

• Part flatness improved by 26%

• Peak spindle power reduced by 46 percent

• Improved tool life through reduction of peak axial forces

• Cycle time reduced by 10 seconds

Z Force vs. Time

Z Fo

rce

(N)

Time (sec)

-500

OptimizedBaseline

0

AUTOMOTIE CASE STUDY: ENGINE BLOCK

140+ VALIDATED MATERIALS DATABASE

AdvantEdge and Production Module have an expanding library of more than 140 materials that have been developed and validated by Third Wave Systems engineering staff using proprietary material characterization technology that our engineers convert into custom material models. Third Wave Systems’ expertise ensures the user can be confident of the results and analysis completed using Third Wave Systems modeling products.

To learn more about Third Wave Systems products and services, visit www.thirdwavesys.com. If you'd like to setup a live web demonstration for AdvantEdge or Production Module, contact us at sales@thirdwavesys.com, or +1-952-832-5515.

ABOUT THIRD WAVE SYSTEMS, INC. > Third Wave Systems develops and sells premier materials based modeling software and services for machining solutions. Innovative manufacturing companies implement these solutions to dramatically reduce costs of machined components, accelerate design cycles, improve part quality and get to market faster.

CASE STUDY

One of the benefits Makino receives from utilizing Third Wave Systems product, Production Module, is the force calulation when the insert geometry is irregular. This example shows a HFM cutter with three edged inserts. The orientation and geometry of such inserts makes challenging the manual estimation of cutting forces. For this particular tool is important to keep the cutting forces below the maximum allowed by the bending moment limit.

Tool allows 4032 N of side load

Analysis of bending moment for long reach tools

» HSK 100 with 45000 N of claming force » 1250 Nm of allowable bending moment » Maximum side load on tool = 1250 [Nm]/GL [m]

Diameter Dc 63.000 mm 2.480’’

Teeth Zn 5

Cutting Speed Vc 200.0 m/min 656.2 sfm

Feed/tooth fz 0.600 mm/tooth 0.0236’’/tooth

Axial Immersion ap 1.500 mm 0.059’’

Radial Immersion ae 63.000 mm 2.480’’

Metric Inch

Production Module uses physics to simulate the machining process. In this case, it displayed heavy roughing on the fluid-end removing about 42.5 cubic inches a minute (a little less than ¾ of a liter of steel per minute). Production Module helps Makino visualize spindle usage by calculating the power demand and illustrating how close this demand is to the continuous operating specification.

Utilization of spindle capability for heavy roughing

Diameter Dc 63.000 mm 2.480’’

Teeth Zn 5

Cutting Speed Vc 200.0 m/min 656.2 sfm

Feed/tooth fz 0.600 mm/tooth

0.0236’’/tooth

Axial Immersion ap 1.500 mm 0.059’’

Radial Immersion ae 63.000 mm 2.480’’

Metric Inch