Simulation and virtual analysis of machining operations for industrial needs

Machining operations have special economic importance due to their late position within the industrial manufacturing chain. The quality of products manufactured in machining operations, in terms of form, dimensional integrity, surface topography, and subsurface characteristics, is determined largely by the interactions between the tool and the workpiece along with the corresponding process. Considering this complex relationship, it would be ideal to avoid mistakes for components that have already completed a large part of the added-value manufacturing chain as well as to set up optimal process conditions in order to achieve a reliable and cost-effective production. A virtual process simulation can prove valuable in reaching these goals. For today's industrial needs, 3-D Finite Element Method (FEM) simulations can assist in determining optimal process cutting parameters and tool performance for individual applications. The computational modelling tools used for these simulations undergo constant optimization and refinement. In this context, research at WZL and Fraunhofer IPT has been performed. Based on FEM simulations and machining experiments, the correlation between cutting parameters, tool, and workpiece properties has been carried out. The results are then transferred into an immersive Virtual Reality (VR) environment in order to visualize and analyze the modelled process. The application of Virtual Reality provides an intuitive means of interacting with the model and facilitates better comprehension of material formation due to stereo visualization. This paper focuses on these recent advances in FE modelling and virtual analysis of machining operations with special attention paid to the application of 3-D modelling for industrial needs.