Presentation at the 2008 Defense Manufacturer\'s Conference (DMC), Orlando, FL: The advent of finite-element modeling based systems has ushered in an era of physics-based prediction of machining operations, giving engineers new insight into designing machining strategies. Some technologies are being employed as machining process development tools. Others are being applied by companies following the tool path generation process in the computer-aided manufacturing (CAM) software systems. Further, other software technologies are evolving within the CAM software systems users currently operate, offering dramatic reductions in machining cycle times by affecting air cuts and feed rates. But users still wonder how to apply these various approaches; they puzzle over what approaches work for their shop practices. Attendees described after this presentation that they had a clearer sense of how strategic changes in machining approaches and implementation of the right technology for a given manufacturing condition can make all the difference.

1. Manufacturing Simulation for Precision Machining Operations Finding Efficiency in Machining Today Dec 4, 2008 B r i a n K i n d i l i e n M a n a g e r, P r o c e s s M o d e l i n g a n d S i m u l a t i o n C C A T DMC 2008

3. Helping to Strengthen our Nation Strengthening Economic Competitiveness Education Economic Development Technology Innovation Collaboration E-learning Project Based Interdisciplinary Multicultural

5. Machining Optimization Codes Studied Analysis and design of metal forming, heat treatment, and machining processes Deform (Scientific Forming Technologies Corporation) Optimization of existing machining processes NALI Machining Gamer Changer (CCAT-NALI, Third Wave Systems, and CNC Software collaboration) Optimization of existing machining processes Mastercam Intelligent Feed Rate Optimization (CNC Software, Inc.) Optimization of existing machining processes VERICUT OptiPath (CG Tech) Optimization of existing machining processes AdvantEdge Production Module (Third Wave Systems) Design and optimization of new machining processes Multiple Response Statistical Optimization (MRSO) (CCAT-NALI and UTRC) Collaboration) Design and optimization of new machining processes AdvantEdge FEM (Third Wave Systems ) Application in Machining Process Optimization Technology

6. Optimization Technology Comparison Capabilities  Has this capability  Not applicable  Currently functions only with Mastercam Limited to 2- and 3-axis milling Requires Vericut with controller modeled. NC program looses association with CAM Substantial learning curve Requires knowledge of AdvantEdge and Minitab software Time to run simulations is substantial Limitation Ability to analyze a variety of parameters throughout the path within industry accepted CAM system Direct link to industry accepted CAM system Significant ease of setup and use for VERICUT users Ability to analyze a variety of parameters throughout the path Reduces number of simulations required to achieve optimal results Robust finite element modeling of machining strategies Unique capability       Association with CAM program Feed rate changes to available lines of code only, no added or modified geometry Breaks up cuts for smooth ramp up and down of tool feeds Option to break up cuts for smoother feed transitions and elimination of air cuts Feed rate changes to available lines of code only, no added or modified geometry   Break cuts Up to full 5 axis 2 and 3 axis Up to full 5 axis Up to full 5 axis   Axes Chip load Chip Load Chip load Power Power Temperature Temperature Primarily tangential force balancing Volume of material removed Volume of material removed Primarily tangential force balancing Optimize for machine cycle time, tool wear, chip control, etc. via AdvantEdge Optimize for machine cycle time, tool wear, chip control, etc. Optimization Approaches NALI Machining Gamer Changer Mastercam Intelligent Feed Rate Optimization VERICUT OptiPath Production Module Multiple Response Statistical Optimization (MRSO) AdvantEdge FEM Technologies

7. Gcode Comparison Gcode Before Optimization Gcode After Optimization Third Wave Systems AdvantEdge Production Module Matercam Intelligent Feed Rate Optimization Gcode Before Optimization Gcode After Optimization CG Tech OptiPath Gcode Before Optimization Gcode After Optimization

8. Machining Implementation Scenario Design 3D CAD Integrate Optimization Tool with CAM! Improved NC Code #2 Advanced Machining Implementation Scenario Machining Game Changer Scenario Seeking companies for application to beta test process. Current participants include: NIST ■ NCDMM ■ TechSolve ■ CNC Software Soliciting participant recommendations from MAI Generate NC code CAM Download NC code Analysis of Process TWS CutPro NC Code #1 Additional Effort to Analyze Processes, with another piece of Software….. Multiple copies of NC Program to Track….. Not Associated to CAM Validate Process Machine Simulation NC Code #1 Minimal Additional Effort to Analyze Processes included in the CAM process…. Only one version of NC Program to track….