Home

CutPro

1. mh a jF m m oO CL wy mh Cutter Rotation w tel SS 65 490335 Options Coord s Zoom Reset Y 2569 144527 MAL Inc User Manual for CutPro exe 163 Temperature is calculated at a series of increments along the cutter rotation Please refer to Section 3 1 10 TEMPERATURE PROPERTIES for more information regarding Temperature Simulation 5 4 1 2 TOOL TEMPERATURE DISTRIBUTION Figure Mo 1 File Edit View Insert Tools Window Help JO MH S RAASL SEA y 1 Tool Temperature Distribution C MATLAB is required to run in order to plot the Tool Temperature Distribution Please refer to Section 3 1 10 TEMPERATURE PROPERTIES for more information regarding Temperature Simulation MAL Inc User Manual for CutPro exe 164 5 4 1 3 TOOL TEMPERATURE CONTOUR ON XY PLANE 0 x File Edit iew Insert Tools Window Help DaES RAAS PEr y q0 Tool Temperature Contour on sY Plane C MATLAB is required to run in order to plot the Tool Temperature Contour Please refer to Section 3 1 10 TEMPERATURE PROPERTIES for more information regarding Temperature Simulation MAL Inc User Manual for CutPro exe 165 5 4 1 4 CHIP TEMPERATURE DISTRIBUTION ioj xI File Edit wiew Insert Tools Window Help D ng kan per CHIT TEMPERATURE including the cubic interpolation C Distance Along Chip Thickness ra T 0 2 0 4 0 6 0 5 1 Distance Along Tool Chip Interface rm
2. ME Geometry Parameters Tool Shank Diameter A mm haso FRF Measurements Files Inner Shank Diameter A1 rnm a4 ial Soci Gauge length B mm pgp Holder Shank Diameterd C mm 41 04 Holder Shank Diameters C1 mm 3302 Max Tool Depth D mm 526 0 Taper Shank Length E mm B26 CO Flange Length L mm 20 Be identification oF ae Shank Diameter Figure 6 9 22 Tool Tool Holder assembly to spindle Identification Geometry parameters Press Next to input the FRF impact measurements MAL Inc User Manual for CutPro exe 224 6 9 5 2 2 IDENTIFICATION IMPACT MEASUREMENTS Import the 3 measure FRF files in Figure 7 9 2 18 Figure 7 9 2 19 and Figure 7 9 2 20 respectively The measured frequency response files have to be displacement force FRF s C ReceptanceCoupling File Options Help e lt lt gt Open Save Back Next Spindle r Impact Measurenents Be identification Geometry Parameters BE impact Measurements Me Coupling Import TF12 Import TF2 Exit Figure 6 9 23 Tool Tool Holder assembly to spindle Identification Geometry parameters Press the Run Identification Button to start the Identification procedure Running Identification Figure 6 9 24 Running Receptance Coupling Engine I dentification It will open a command window and will take a few minutes depending on the frequency selection and the speed of the computer Refere
3. 19 05 Depth of Cut mm Spindle Speed rpm ee E u s 1 0193E 04 Options Coord s Zoom Reset sB 22222 Figure 9 8 3 1 Multiple Analytical Stability Lobes result from the example The stability lobes for the three steps are illustrated in three different colours To ensure the stability of the entire process select a point which is stable for all three steps 38 4 EXAMPLE C OBTAINING CUTTING COEFFICIENTS IN MILLING This example illustrates how to identify cutting coefficients in a milling process with obtained experimental cutting forces The following steps are contained in the example file Ex07_CuttingCoef csf Select the Advanced Milling module Select the Cutting coefficient identification mode Click Next to go to the General Output tab Note that no selection can be made on this tab MAL Inc User Manual for CutPro exe 249 Click Next to go to the Machine amp Tool Cutter tab Only Cylindrical end is available for Cutting Coefficients Identification mode Enter the number of flutes on the tool Click Next to go to the Machine amp Tool Cutter Properties tab It does not matter what material you select Click Next to go to the Machine amp Tool Structural Flexibility tab The tool is assumed to be rigid in Cutting Coefficients Identification Click Next to go to the Workpiece Material tab It does not matter what material you select Click Next to go to the Workpiece Structural Flexibility tab Th
4. Please refer to Section 3 1 6 WORKPIECE MATERIAL TAB on page 95 for details MAL Inc User Manual for CutPro exe 153 3 4 6 WORKPIECE STRUCTURAL FLEXIBILITY TAB D CutPro Uintitied cel Boring Structural Flexibilly lt a hel E Tats Camel Of Genera Machine Tool Wekpiece CutingCondtions Temperature banie lunchon ie Fad E ilii C Drame pma lp setect a ld be other Shen ASL tl the fie wall be converted to ASCE and saved vil ihe Materia Figure 3 4 6 Workpiece Structural Flexibility tab in the Boring Module This tab allows you to modify the structural flexibility of the workpiece Note that this version of CutPro does not yet support the dynamics of the workpiece for boring processes iu MAL Inc User Manual for CutPro exe 154 3 4 7 CUTTING CONDITIONS TAB Wa CutPro Untitled csf Fie Simulation Results Tools Window Help eo CMA Mers pem Save Properties Eum Arg Eum teme Plot All 7 gt Modal Mal F Mal Machining Boring Simulation Properties Process 3 RE CNUNG Conditions l lt gt Hide x y CutEnG Conditions Back Mext Tabs Cancel OK General Machine amp Tool workpiece Cutting Conditions Temperature Feedrate c mmr m5 Surface speed W m min 250 Spindle speed N RPM 1808 579 Diameter ofthe hole D mm 42 65 Depth of cut fa mrm oe 75 Length of cut L mm a Humber of
5. 55 3 SIMULATION PROPERTIES WINDOW S TABS AND DEFI NITI ONS 3 1 2172 AXIS MILLING MODULE 3 1 1 GENERAL SIMULATION MODE TAB a CutPro Untitled csf File Simulation Results Tools Window Help y Es D H Properties Run a Plot All A Modal MalTF Mer Open Save Run Temp es Process i Gareraf eV lt gt fil Y PaO WOU Back Neck Tabs Cancel OK General Machine amp Tool Workpiece Cutting Conditions Temperature E a Simulates cutting forces tool vibrations surace finish spindle Senet een en Sears power and spindle bending moment in a single time domain r Stability lobes in time Use this mode to simulate stability lobes within a narrow speed range domain for a complicated cutter Othermise see below r Single analytical A fast analytical stability lobes prediction solved in a frequency stability lobes domain g Multiple analytical Generates stability lobes with axial and radial depths of cut and stability lobes spindle speed r Optimize variable Automatically calculates pitch distribution at a specific spindle pitch speed for a given number of flutes r Cutting coefficient Automatically identifies the cutting coefficients based on files identification defining Y and cutting forces Simulation Mode Figure 3 1 1 General Simulation Mode tab of the 272 Axis Milling module This tab allows you to choose the simulation mode There are six Si
6. Edit Equation Depth of cut 1 Back Delete Nest Depth al mn Figure 3 1 81 Variable cutting coefficient along the axial depth of cut model frame in Material Editor window The following parameters are used in order to define variable cutting coefficient along the axial depth of cut model Table 3 1 212 Parameters for Variable Cutting Coefficient along the Axial Depth of Cut model Depth a Depth of cut for which the currently displayed parameters are applicable up to 18 depths of cut may be defined Use the Back and Next buttons to move between depths of cut Back Go to the previous depth of cut Delete Delete the current depth of cut Next Go to the next depth of cut Kte Tangential edge force coefficient N mm Kre Radial edge force coefficient N mm Kae Axial edge force coefficient N mm Kte Tangential shearing coefficient N mm Ke Radial shearing coefficient N mm Kac Axial shearing coefficient N mm2 MAL Inc User Manual for CutPro exe 109 ORTHOGONAL TO OBLIQUE CUTTING TRANSFORMATION The force model is based on orthogonal cutting tests For this model extensive experimental tests that provide material properties which are applicable to any cutting tool geometry need to be conducted In the following figure you can see the Orthogonal to oblique cutting transformation model frame in the Material Editor window Orthogonal to oblique cutting transtormation model Kee N mm T
7. Measurement 1 9 6716e 07 77373 07 5 0308 07 3 8686e 07 4 4 A4 A 1 93436 07 f o o000e00 Magnitude mAN 1600 2000 2500 3000 3500 4000 4500 5000 Frequency Hz je o bG WDS wns G H M 3372 164946 Options Modes Cursor zoom Reset Real Imaginary Magnitude f 1 391 5E 0E FAF file opened C CutPro4Program 00004 tmp Z Figure 6 5 2 A sample modal analysis with four modes added 6 5 3 DELETING A MODE Select the mode you want to delete from Modes Table just below the toolbar Then select Delete Mode under the Modes menu or click the Delete Mode button on the toolbar 6 5 4 PLOTTING ALL THE MODES Select Plot Modes under the Modes menu or click the Plot Modes button on the toolbar This automatically combines all the modes without optimization and displays the final transfer function fit You can click on the thick Arrow buttons to see the Subsequent measurements that have been automatically fit in the background Ery MAL Inc User Manual for CutPro exe 205 6 5 5 OPTIMIZING THE MODES If you want more accuracy you can optimize the modes you have identified by selecting Optimize under the Modes menu or by clicking the Perform Optimization button on the toolbar The optimization uses a two stage linear least squares algorithm You can select one to three parameters to optimize below the parameters are then added to the Modes Table and the fitted FRF is plotted within the selected range
8. yY Siructural Fiexibiity Back Next Tabs Cancel OF General Machine amp Tool Workpiece Cutting Conditions Temperature Workpiece Model f Rigid C Dynamic vibrations E Static deflections Workpiece Dynamics Mode Dynamic Parameters Direction E va ra Mode no 1 1 1 Measured tt file ee Nat freg Hz i000 fioa fiooo Hodal residue data files Damping ratio 0 05 0 05 0 05 Stiffness M m 100E 21 1008 07 F100 21 E E f Dynamic parameters Bia E Mbi on Boring Drilling Hilling Advanced 4 Previous Delete nsert Herst gt Prediction of cutting Material Structural Flesibility Figure 3 1 89 The Workpiece Structural Flexibility tab This tab is the same as the one on Section 3 1 5 MACHINE amp TOOL STRUCTURAL FLEXIBILITY TAB on page 89 3 1 8 CUTTING CONDITIONS MILLING MODE TAB You can define milling modes on this tab Depending on the tool type you specify on MACHINE amp TOOL CUTTER TYPE TAB the parameters on this tab could be different In the following you will be finding the parameters for each tool type The different tool types are Cylindrical Endmill Ball Endmill General Endmill and I ndexable Cutter 3 1 8 1 CYLI NDRI CAL ENDMI LL The following modes are available for cylindrical endmill Down milling Up milling Slotting MAL Inc User Manual for CutPro exe 115 Face milling For each mode you define cutting parameters i e Feed Rate mm flute
9. 28 4 Density gcn 11 1 Cancel Figure 3 1 44 Material Editor window for Fixed Materials The window displayed in Figure 3 1 40 allows you to view the properties of a tool material that has fixed data Since the data is fixed you cannot save any changes you make to the parameters 3 1 4 2 TOOL PROPERTIES Radius r mm 35235 radius center Ar mm He Length L mm J z2 2 radius center Az mmn 4762 First bearing position ram 20 Comer radius FJ rm 4762 Helis i 30 Flute height h mm 4762 Relief 5 Laie Taper angle ash per ang AIT 0 Lead distance mm 10 Clamp stiffness Kc Nr 2 DOE 05 Flute type Constant Heli Mod elasticity MPa 2 0FE 11 l Geometry type Tangent radius Serrated Cutter File View Figure 3 1 45 Tool Properties in Machine amp Tool Cutter Properties tab On the Machine amp Tool Cutter Properties tab you can define parameters of the tool such as radius length first bearing position helix relief and rake angles clamp stiffness modulus of elasticity x and z radius centers corner radius flute height tip and taper angles lead distance flute type and geometry type MAL Inc User Manual for CutPro exe 80 based on the tool type you have specified in Section 3 1 3 Machine amp Tool Cutter Type tab The window shown in Figure 3 1 23 that displays the general look of the selected tool on the right hand side of the Simul
10. desired freq range MAL Inc User Manual for CutPro exe 231 6 9 8 PROCEDURES amp RECEPTANCE COUPLING FLOW CHART H33 FRF Measurements at the Spindle end with the small blank Gil Assembled FRF Measurements at the tool tip G12 Assembled cross FRF measurements by applying the force at the joint location but measuring at the tool tip RDOF Rotational degrees of freedom RDOF FRFs at the joint Ho Measure G11 and G12 RDOF Extraction FEN Tool density E lengths Receptance Couple at tool tp display MAL Inc User Manual for CutPro exe 252 6 9 9 LIMITATION OF RECEPTANCE COUPLING The accuracy of the Receptance Coupling software is depending on the measurement noise This software is used for guidance not an absolute final solution The accuracy of the receptance coupling technique depends on accurate identification of the joint dynamics of the substructures at the assembly joint and the FRFs of each substructure MAL Inc User Manual for CutPro exe 233 7 MILLING ANIMATION Milling Animation allows you to see how the chips are removed and how the workpiece and cutter vibrate Surface finish is graphically represented at different axial positions along the depth of cut When you open the Milling Animation program by selecting Tools gt Milling Animation from the Main CutPro Window the most recently generated animation data is automatically loaded if there is any available fi
11. lAJlo R w ele Frequency Hz Residue Fel m Residue Irn m Modal Stiffness Mass kg TestFAF11 frf Measurement 1 4 671 6e OF Tar se OF 5 00 50e OF 3 0606e 07 1 8a4se U7F 0 0000e00 0 500 41000 1500 2000 2500 3000 3500 4000 4500 4000 Frequency Hz ee ee ee ways G H mM x 4060 07759 Options Modes Cursor zoom Reset Real Imaginary Magnitude f 2332E 07 q lt lt T perem a E mt m o 4 FAF file opened C CutPro Progran 0000 trap 2 Figure 6 5 1 Sample modal analysis with a mode selected between 3200Hz and 4500Hz MAL Inc User Manual for CutPro exe 204 6 5 2 ADDING THE MODE Select Add Mode under the Modes menu or click the Add Mode button on the toolbar The mode you have identified is added to the Modes Table displayed just below the toolbar This process may be repeated until the desired number of modes is selected See Figure 6 5 2 AA 3D Modal Analysis Ex FRF mod Oj zial Hal o R wl lae E Mode Shape Frequency Hz Damping Residue Re m Residue Im me Modal Stiffness Mass kg a a 4 7921E 02 r 5939E 03 0 0000E 00 6 4606 06 2 3231E 08 25 625 2 T B 6601E 02 5 261 7E O2 0 0000E 00 1 1219E 04 1 567 7E 07 1 067 3 T o 94956 02 6 BOB4E 02 0 0000E 00 S043E 04 1 47 95E 07 0 468 4 T 2 19985E 03 1 64208 02 O 0000E 00 2063E 04 5 7 298E 07 0 300 TestFARFes1 1 trt
12. uncut chip area Static deflections spindle power and torque The latter simulates the stability lobes within a narrow frequency range 3 4 2 GENERAL OUTPUT TAB This section allows you to specify which results you want CutPro to output in simulation To include a result in the simulation output check the box next to it MAL Inc User Manual for CutPro exe 148 D CutPro Untithed ics File Smuain Resuks Tool Window Help Bereta I Machines Too Waikpiece Check the output you ward io cave fe Culting heces fv Unout Chp Area fy pridi power amp torque Figure 3 4 2 General Output tab of the Boring Module Cutting Saves forces in feed radial and tangential Forces directions Uncut Chip Saves uncut chip area Area Static Saves boring bar radial deflections deflections Spindle Saves spindle power and torque power amp torque amp The Output Tab is applicable only to the Static Analysis simulation mode MAL Inc User Manual for CutPro exe 149 3 4 3 MACHINE amp TOOL TOOL PROPERTIES TAB D CutPro UntithedLcs File Smin Pasults Took th Hen A hapal un Tere D W toring Sirnulat in Properties New Open Save Machine amp Too TEPI Toal Properties Re gt a ee 7 General m wWwokpece Cutting Conditions Tempershue Select cufting tool Iimpat Humb of inae i ike Poe ey ERE Length of boing bar Clim fing Diameter of boring bar D m
13. 02 Se mre WORKPIECE VIBRATIONS IN X AND DIRECTIONS Same as Tool Vibrations in X amp Y Directions 5 3 4 UPMILLING SURFACE FINISH The first column is point number The second column is X coordinate value of the point mm The third column is Y coordinate value of the point mm The fourth column is Z coordinate value of the point mm Example 0 0000E 00 2 9167E 01 2 9078E 00 8 8399E 02 1 0000E 00 2 9167E 01 2 8585E 00 9 2159E 02 2 0000E 00 2 9167E 01 2 8092E 00 9 5662E 02 oye Fee DOWNMILLING SURFACE FINISH See Upmilling Surface Finish above 5 3 6 CHIP THICKNESS MIDDLE OF CUT The first column is time sec The second column is chip thickness for flute number 1 mm MAL Inc User Manual for CutPro exe 190 The third column is chip thickness for flute number 2 mm The fourth column is chip thickness for flute number 3 mm The fifth column is chip thickness for flute number 4 mm The number of column will be change with number of flute Example 0 0000E 00 0 0000E 00 3 0453E 03 0 0000E 00 0 0000E 00 1 2500E 04 0 0000E 00 3 7579E 03 0 0000E 00 0 0000E 00 2 5000E 04 0 0000E 00 5 4013E 03 0 0000E 00 0 0000E 00 one oe SPINDLE POWER The first column is time sec The second column is instantaneous spindle power HP The third column is cumulative average spindle power HP Example 0 0000E 00 2 8183E 01 2 8183E 01 1 2500E 04 2 8656E 01 2 8421E 01 2 5000E 04 6 0222E 01 4 1802E 01 5 3 8 SPINDLE BENDING MO
14. 1 the tool sF Cutting Forces Untithed csF Cutting Forces With nn ee ta hw ROR aS x 0 164773 Options FFT Coord s Zoom Reset T 15216929 Figure 3 1 3 Cutting forces in x y and z directions z i Oo LL dey Cutting Force Untitled csF X Cutting Force T 00 0 05 0 10 ail l Time sec w wa BOR fws x 0 164323 Options FFT Coord s Zoom Reset f 82 350447 Figure 3 1 4 Cutting forces in x direction MAL Inc User Manual for CutPro exe 58 ds Y Cutting Force Untitled cs Y Cutting Force iy eh kO EOS pws x 0 161045 Options FFT Coords Zoom Reset 201 368531 Figure 3 1 5 Cutting forces in y direction JPZ Cutting Force Untitled csf Z Cutting Force 0 00 0 05 Time sec te ef BIOs fas 0 165668 Options FFT Coord s Zoom Reset Y 13 991 327 Figure 3 1 6 Cutting forces in z direction F MAL Inc User Manual for CutPro exe 59 Resultant Force in the X Plane Untitled cst l Ioj x Resultant Force in the xXY FPlane 400 THN 0 00 0 05 0 10 0 15 cli i i m LL Time sec et ea TE x 0 165401 Options FFT Coord s oom Reset Y 363 401307 Figure 3 1 7 Resultant cutting forces in xy plane FR Nia FY E Tangential Cutting Force Untitled csf ioj x Tangential Cutting Force 0 00 0 05 0 10 Hil Time sec Force N D ta tel BES jms Options FFT Coord s o0
15. 10 4 MATLAB is required to run in order to plot the Chip Temperature Distribution Please refer to Section 3 1 10 TEMPERATURE PROPERTIES for more information regarding the Temperature Simulation F MAL Inc User Manual for CutPro exe 166 5 4 1 5 CHIP TEMPERATURE CONTOUR lox Fie Edit View Insert Tools window Help JO HS LAASY PER y 140 Contour of Chip Temperature on the x y plane C s00 450 400 350 300 250 Distance Along Chip Thickness m 200 150 0 0 2 0 4 0 6 0 5 1 1 2 1 4 1 6 Distance Along Tool Chip Interface m y 104 MATLAB is required to run in order to plot the Chip Temperature Contour Please refer to Section 3 1 10 TEMPERATURE PROPERTIES for more information regarding the Temperature Simulation MAL Inc User Manual for CutPro exe 167 5 4 2 TURNING MODULE PLOTS 5 4 2 1 CUTTI NG FORCES 10 x Cutting Forces S m m ci i _ Oo LL Time sec w le EOS pws 1 829714 Options Coord s Zoom Reset Y 87 091957 This plot shows the cutting forces in the X Y and Z directions in three different colours Please refer to Figure 2 1 1 in Section 2 1 Milling Module for the axes definitions of X Y Z Eny MAL Inc User Manual for CutPro exe 168 5 4 2 2 TANGENTIAL FORCE e Tangential Force Untitled cst 5 x Tangential Force a Force N 4 Time sec wih Be Wwe 10 667508 Options Coord s oom Reset Yao ane
16. 3 MAL Inc User Manual for CutPro exe PNTS 1 REALM 0 WN 503 252663429737 ZETA 9 68088610851847E 02 WN 667 318567093533 ZETA 5 15631722455325E 02 WN 891 394563382914 ZETA 5 93480547124278E 02 LOCNS 0 RESRE 1 92775517514935E 05 RESIM 3 65695200216576E 05 RESRE 2 90756637986845E 05 RESIM 3 58422199737442E 05 RESRE 1 54820897083893E 05 RESIM 4 98397635177649E 05 254 9 3Appendix A3 Dynamic Parameters This uses the following dynamic parameters It only allows for a single dominant mode in each of the X and Y directions Natural frequency Natural frequency of the system in Hz Damping ratio Damping ratio for that mode Stiffness k Stiffness of the system N m Transfer function values are calculated using following equation in frequency domain o k ae 2 w O 1260 MAL Inc User Manual for CutPro exe 255 9 4Appendix A4 How CutPro Calculates Dynamic Chip Thickness Previgualy cut amp urlace Newly cul au mace Dynamic Chip Thickness MAL Inc User Manual for CutPro exe 256 9 5 Appendix A5 Geometric Figures for Tools 9 5 1 General Tool Geometry Parameters Figure Cutter Parameters Pp Radius of cutter mm R Corner radius mim R r coordinate of corner radius center mm R z coordinate of corner radius center mm a Slope ang for the first line degree P Slope ange for the second line degree h Valid cutting edge height mm M
17. 32 55 164 ANALYTICAL STABILITY LOBES 38 187 188 Average cutting coefficient model Material editor 110 Axes definition 30 B Bi linear force model Equations 248 Bi linear force model Material editor 112 BORING 49 144 C CHIP TEMPERATURE CONTOUR 163 CHIP TEMPERATURE DISTRIBUTION 162 D Down milling 119 Dynamic chip thickness 240 Dynamic parameters 95 205 Dynamic parameters Machine dynamics mode 239 E Equation editor 102 104 Example files 220 Exponential chip thickness Equations 250 Exponential chip thickness Equations 250 Exponential chip thickness model Material editor 113 Export Results 185 FACE MILLING 122 FRF files about 206 FRF Files opening 197 G Getting started 17 H H33 FRF 209 High order force model Equation 252 High order force model Equations 252 268 High order force model Material editor 114 I Insert editor 90 Installing CutPro 9 Introduction 9 L License Information 29 M MALDAQ 14 MALITF 13 Material editor 99 Milling animation 218 Modal analysis 190 MODAL ANALYSIS 13 190 192 193 194 Modal parameters in CutPro 205 Modal residue data files Machine dynamics mode 238 Modes selecting Modal analysis 199 N Number of flutes 72 O Opening FRF Files 197 Optimize Variable Pitch 128 Orthogonal to oblique cutting transformation 99 247 Orthogonal to oblique cutting transformati
18. 9 RECEPTANCE COUPLING sssssssssnsnnnnnnnnnnnnnnnnnnnnnnnnn 210 Beek INTRODUCTION corer a E sacsantanteese 210 O59 ADVANTAGES seoan A E EEA 211 6 9 3 FUNCTIONS OF THE SOFTWARE irispsssgisrririastesognisrusri 211 6 9 TOO COUPLING aenn EAE EE 212 COUPLING OF HOLDER AND TOOL ASSEMBLY TO SPINDLE 221 6 9 5 221 69 6 TOOC LENGE TONING cerni EEA 226 6 9 7 WAYS TO MINIMIZE THE NOISE AND INCREASE ACCURACY OF THE PREDICTION Sxcicivce aevacaiamescmetmncckatsanacncse 230 6 9 8 PROCEDURES amp RECEPTANCE COUPLING FLOW CHART 231 6 9 9 LIMITATION OF RECEPTANCE COUPLING nsss 232 MAL Inc User Manual for CutPro exe 7 MILLING ANIMATION ccc ceccnnennscnsensennsensensenes 233 o EXAMPLES siedursstiscemsntedeseiiessteesennesnaeiees 235 8 1 EXAMPLE FILES sirrien pernai 235 8 1 1 Ex01_SingleAnalytical CSf cc ce cccccc cece esse eee eeeeneees 235 8 1 2 Ex02_SingleTime_6000rpm_3MM CSf c cece eeeeee eens 235 8 1 3 Ex03_SingleTime_14300_ 6MM CSf c cece cece eeeeeeees 235 8 1 4 Ex04_MultipleAnalytical csf cccceceeeeeeeeeeeeeeeeenenens 235 8 1 5 Ex05_Optimumpitch_5OOO CSf cee ece eee ee seen ee eeeeees 235 8 1 6 Ex06_SingleAnalytical Var cCsf cccceeeeeeeseeeeeeeeeeees 235 8 1 7 EXO7 CUtUNOCOG CS snscncaanesasccsttnescneatsdtees tweeeendan cane 235 8 1 8 Ex08_SingleTime_BallEnd CSf sssesessssenerannnnnrsrsresns 235 8 1 9 Ex09_SingleTime_GeneralEnd csf cccceceeeeeeeeeeeeees 236 8 1 10 Ex10_
19. AL356 T6 from the material drop down menu Click Next to go to the Workpiece Structural Flexibility tab For the purpose of this example the workpiece is assumed to be rigid Click Next to go to the Cutting Conditions Milling Mode tab The parameters to be entered are exactly the same as in the previous section The Spindle Speed is specified to be 6000RPM and the number of revolutions is entered as 15 The sampling frequency scale can be entered as 10 Note that the Material Removal Rate and the Surface Speed are dependent on the other parameters entered Click Next to go to the Cutting Conditions Other Parameters tab No other parameters can be entered Click Next to go to the Temperature Properties tab We are not interested in the temperature simulation for this process Click OK Click Run to run the simulation MAL Inc User Manual for CutPro exe 241 To see the tool vibrations click Results gt Plot gt Tool Vibration Click FFT on the Tool Vibration window toolbar 4 FFT Tool ibration EX02_SingleTime_6000_ mm csf O x Tool Vibration FFT a 2054 687256 Y 6 346846 05 Deflection mm 1000 2000 Frequency Hz oe U eS ps s 351 503372 Options Harmonics Coord s oom Reset VT esasa Figure 9 8 2 3 Tool vibration at 6000RPM in frequency domain Notice that there is a high peak at around frequency 700Hz and a lower peak at around 400Hz The 700Hz peak is due to the natural frequ
20. Back Nexk Tabs Cancel OK Summation Moge General Machine amp Tool Workpiece Cutting Conditions Temperature f Static analysis Predicts static cutting forces c Analytical stability Use this mode to simulate stability lobes within a narrow speed lobes range Cutting coefficient Automatically identifies the cutting coefficients based on tiles identification defining Tagential Radial and Feed cutting forces Figure 2 2 6 Cutting Coefficient I dentification mode is highlighted by the red box in the General tab of the Turning module This mode is under development MAL Inc User Manual for CutPro exe 2 3 BORING MODULE n f Frequency of the chatter Hz n Spindle speed frev sec No The number of full waves fe Phase shift hehweaen inner and outer waves Figure 2 3 1 Geometry and axes definition of boring process MAL Inc User Manual for CutPro exe 49 50 Die wk SINGLE INSERT MODULE CutPro Untitled csf File Simulation Results Tools Window Hel D fs Mew Open Save Properties Machining Process Figure 2 3 1 Single Insert Boring module 2 3 1 1 STATIC ANALYSIS M CutPro Untitled csf File Simulation Results Tools Window Help oe amp kt l L ww p Mew Open Save Properties Run Run Temp Plot ll Modal Mal F TE bo Wi 1 Machining SEA E ene se Process General Simulation Mode lt gt Wel A Back Next Tabs Cancel OK A E
21. Figure 2 1 2 2 Axis Milling module F MAL Inc User Manual for CutPro exe 31 CutPro Untitled cst File Simulation Results Tools Window Help Oo fh ie ae New Open Save Properties Run Run Temp Modal Machining BSiiibrae ELE Process General gt ay x Jf Simulation Mode Meck Tabs Cancel OK General Machine amp Tool Workpiece Cutting Conditions Temperature m Single analytical A fast analytical stability lobes prediction solved in a frequency stability lobes domain T Miling process Simulates cutting forces tool vibrations surface finish spindle simulation power and spindle bending moment in a single time domain e Multiple analytical Generates stability lobes with axial and radial depths of cut and stability lobes spindle speed Stability lobes in time Use this mode to simulate stability lobes within a narrow speed range domain for a complicated cutter Otherwise see belom m Optimize variable Automatically calculates pitch distribution at a specific spindle pitch speed for a given number of flutes gt Cutting coefficient Automatically identities the cutting coefficients based on files identification defining Y and lt cutting forces simulation Mode LI LIEBE Figure 2 1 3 General tab of 232 Axis Milling module Table 2 1 1 Buttons on Simulation Properties window Back Switch to the previous Back tabs y Next Switch to the next Mext tabs ie ay Hide
22. Inc User Manual for CutPro exe 40 7 an tee e OPTIMIZE VARIABLE PITCH w CutPro Untitled csf File Simulation Results Tools Window Help DO H Pew Open Save ih Properties Run Ma mane Run Temp Plot All Modal MalTF Machining RIDE tet waa tot Process General gt T x mY Hide il Simulation Mode Back Next Tabs Cancel OK ml General Machine amp Tool workpiece Cutting Conditions Temperature Milling Sticke tae diman Simulates cutting forces tool vibrations surface finish spindle lo power and spindle bending moment in a single time domain T r Stability lobes in time Use this mode to simulate stability lobes within a narrow speed range Turning domain for a complicated cutter Otherwise see below C Single analytical stability lobes rc Multiple analytical stability lobes J et eee S A irs Tie variable Pie PUTEO rilling rc Cutting coethicient identification A fast analytical stability lobes prediction solved in a frequency domain Generates stability lobes with axial and radial depths of cut and spindle speed Automatically calculates pitch distribution at a specific spindle speed for a given number of flutes Automatically identities the cutting coeficients based on files defining s Y and cutting forces Simulation Mode Output Figure 2 1 13 Optimize Variable Pitch mode is selected in General tab of the 2 2 Axis Milling m
23. Insert coordinate system MAL Inc User Manual for CutPro exe 87 Rectangular Insert W Figure 3 1 56 Geometry of a Rectangular I nsert Convex triangular inserts are defined by arc radius r and center offset f Convex Triangular Insert w _ Cutting edge Figure 3 1 57 Geometry of a Convex Triangular Insert Table 3 1 133 Buttons on Indexable Cutter Parameters Fdit Insert Allow you to edit insert type This brings up the Type Edit Insert Cutter Types window Copy across When you click on this button the inserts on the flutes same axial level have the same insert type MAL Inc User Manual for CutPro exe 88 Copy down When you click on this button the inserts on the flute same flute have the same insert type Copy to all When you click on this button all the inserts on positions the tool have the same insert type When you click on the Edit insert type button in Figure 3 1 55 the Edit Insert Cutter Types window pops up and you can edit the insert type Insert type tees arate lee New Mame Rectangular 1 Delete Width a roi 5 Length b ron T Figure 3 1 58 Edit Insert Cutter Types window Table 3 1 144 Buttons on Edit Insert Cutter Types window New Allow you to create a new insert The new type must be either Rectangular or Convex Triangular Delete Delete the currently selected insert type Any inserts of this type currently on the indexable cutter will also be removed Zo
24. It accepts standard APT CL files processes them exactly like a real CNC You can define trajectory generation style amplifier settings position encoder velocity tacho generator and acceleration feedback sensors and their resolutions and axis control laws The Virtual CNC system predicts the actual positions delivered by the CNC and plots the reference and predicted actual paths the tolerance violation points along the tool path cycle time by accurately calculating the feed fluctuations caused by acceleration deceleration and control law motor current and position displacement and acceleration of each drive Virtual CNC allows testing of different control laws friction fields motors sensors ball screws and trajectory generation algorithms It runs in stand alone and MATLAB environments It also provides time and frequency domain response of individual drives as well as testing of the CNC on ISO standard test work pieces such as diamond and circle Virtual CNC can be used by manufacturing shop engineers as well as by the CNC designers and professors who teach position control of motion devices MAL Inc User Manual for CutPro exe 17 Virtual CNC offers the following features Step by step CNC Model Generation Detailed CNC Performance Simulation CNC Advanced Controller Design Analysis Tools 1 3 OVERVIEW OF CUTPRO ise Pl STARTING CUTPRO From the Start menu click Programs Select CutPro and click on CutPro f
25. Mmr Ke Mmm d I Koln amp I Edit Equation Figure 3 1 82 Orthogonal to oblique cutting transformation model frame in Material Editor window The following parameters are used in order to define orthogonal to oblique cutting transformation model Table 3 1 223 Parameters for Orthogonal to oblique cutting transformation model Ke Tangential edge force coefficient N mm Ke Radial edge force coefficient N mm Axial edge force coefficient N mm Shear stress N mm Shear angle Friction angle Wwe A gD BI LINEAR FORCE This force model is based on the average cutting coefficient model but the bi linear force model has two cutting coefficient regions The first region has edge coefficients for small chip thickness and the second region has different edge force coefficients after a certain chip thickness limit In the following figure you can see the Bi linear force model frame in the Material Editor window MAL Inc User Manual for CutPro exe 110 Bilinear force model Key Nme Kg EN Key Nem Ka N mm kaam Keg Nn Edit Equation Chip thickness t mrm Figure 3 1 83 Bi linear force model frame in Material Editor window The following parameters are used in order to define bi linear force model Table 3 1 234 Parameters for Bi linear force model Ktc Tangential shearing coefficient 1 N mm Kret Radial shearing coefficient 1 N mm2 Kaci Axi
26. Model f Average cutting coefficient C variable cutting coelticient Semtmechanistic r c Exponential chip thickness alang the axial depth of cut High order mechantstic Orthegonal te oblique cuttin E i arte 4 Sandvik matenals t Bidinear force show Equation Average cutting coefficient model Ke N mm E Kee Mmr 0 K a Mmm E a Mmr 0 K N mm E K solm 0 Edit Equation Figure 3 1 73 Cutting Coefficient Model frame for Al7075 T6 Average Cutting Coefficient model is selected The Equation window that pops up when you click on Show Equation button See Figure 3 1 73 allows you to see both the equations and the definition of the parameters used in the cutting coefficient model Equation ee de K dS K h az dP odot h dz dE dSt K_o h dz d diterential tangential force H dh ditterential radial force H dha ditterential axial torce H aa ditterential cutting edge length mra d ditterential axial depth of cut mn chip thickness tmm Ave tangential edge force coefficient Himm Ave radial edge force coeficient Mt oe axial edge force coelbicient Hram ie tangental shearing coetticient Nm Ae radial shearing coefficient N mm j Figure 3 1 74 Equation window of Average Cutting Coefficient model Click on Done button in Figure 3 1 74 to close Equation window MAL Inc User Manual for CutPro exe 100 Equation
27. Natural The Optimize Natural Frequency button frequency must be depressed Damping The Optimize Damping Ratio button must be ratio depressed Residues The Optimize Residues button must be depressed amp At least one of the three optimization parameter buttons must be selected amp Since this is an iterative search a global optimum is not guaranteed Should the solution diverge the message ERROR will appear in one or some of the cells in the Modes Table To avoid divergence you can limit the optimization to certain parameters any combination including natural frequency damping ratio and residues Furthermore identified parameters may be changed by manually entering a value By double clicking on any parameter in the Modes Table the following dialog box allows the parameter to be overwritten 7 Enter New Parameter Enter new value of damping ratio for mode 1 MAL Inc User Manual for CutPro exe 206 6 5 6 VIEWING THE SHAPE OF A MODE In the Modes Table click on the first column of a mode to display its shape FS Mode Shape 1 Ol x 6 6 SAVING MODAL PARAMETERS The modal parameters as they appear in the Modes Table may be saved by choosing Save Parameters from the File menu or from the button bar A dialog box appears allowing a file name and directory to be chosen The output is a text file with the extension dat The transfer function parameters file example If Modal Model is Complex Mode
28. Point 2 Tool verhang Length Cutter Length Tool Shank Diameter Cutter Diameter L amping Ratio 219 Input the cutting tool dimensions and material you want to couple to the tool holder Measurement Point 2 L is fixed from the previous step in the identification procedure and is given as additional information It is disabled and can not be changed in this step Press Tool Coupling to Start the Coupling Procedure Tool Coupling Figure 6 9 13 Tool Coupling It will open a command window and will take a few minutes depending on the frequency selection and the speed of the computer See Figure 7 9 10 Once the Tool Coupling is completed you can export the predicted FRF at the tool tip or plot in Modal Analysis Export Resulting FAF Plot in MODAL Figure 6 9 14 Tool Coupling Export Resulting FRF or Plot in MODAL After it is completed click Plot the Result on Modal Analysis A new plot should appear on Modal Analysis MAL Inc User Manual for CutPro exe 220 Ai 3D Modal Analysis Untitled Ioj x Fie Modes Results Options Tools sa He lolt TR A ele Frequency Hz Residue Re m Residue Im m Modal Stiffness Mass kg ROOF tr Measurement 1 Magnitude meN Frequency Hz w o A eao RDS WS E H MI 67 644271 Options Modes Cursor zoom Reset Real Imaginary Magnitude Y 1 O00434 FRF file opened C CutFros F rogram 00004 tmp a Figure
29. ReceptanceCoupling File Options Help lal x Optimization Processing Wait Open Save Exit Tool Dimensions Browse Tool HolderSpindle Project Measurement Pomt 2 Limm 10 Tool Shank Diameter O2 rmm 20 Optimization Min Tool Overhang Length 45 mm Cutter Length L1 imm 35 Max Tool Overhang Length 55 mm Cutter Diameter D1 rar 16 Max Spindle Speed 5000 rpm Aun Optimization Damping A atio RAT 0 03 MAL Inc User Manual for CutPro exe 229 Figure 6 9 30 Tool Length Tuning open a Tool Holder Spindle Project MAL Inc User Manual for CutPro exe 230 6 9 7 WAYS TO MINIMIZE THE NOISE AND INCREASE ACCURACY OF THE PREDICTIONS Perform more than 10 impact hammer tests Perform the modal analysis on the short tool FRF Must consider for the high modes as well Use same materials for tools Apply the impact hammers consistently at the same location slight deviation of the appropriate location may cause big deviations Select the of elements depending on the length For example L2 20 mm L1 100 mm you would like to have 1 to 5 ratio for the of elements as well Select the appropriate damping ratio The damping ratio can vary from 1 to 5 depending on materials Select the appropriate frequency range and the resolution Try to have consistent freq range and resolution for all the measurements and simulation Make sure that the bandwidth of the impact hammer is within the
30. Single analytical stability lobes Gene Cutting Conditions Milling made Clockwise up milling Feedrate rornflutel 0 05 O Gir Spindle speed APM Ma Avital depth of cut a mm Na Number of revolutions HA na aE Ste Sampling frequency scale HA Turnin do Cutter Type Cylindrical end fe oir Material Carbide sla H Teeth 4 uniform pitch Structural flexibility Dynamic parameters B tdi Use run out deviations BA ta Radius r mm 9 525 Length L mm te B Up First Bearing Position mm PA B Hairini 30 Drilling Relief Fi Co Rakel 5 Comer radius A mm Na Figure 1 3 7 Results menu in CutPro Report window You can add simulation results to the report by selecting Options and clicking on Add to Report from the drop down menu in the graph window MAL Inc User Manual for CutPro exe 24 t CutPro Untitled cst File Simulation Results Tools Window Help Dow H k Mg Mew Open Save Properties Run Run Temp Plot All Modal MalTF Machining a Stability Lobes Analytical Untitled csf E iol xj Process Stability Lobes Analytical 25 20 15 Depth of Cut mm 10000 20000 30000 40000 S0000 60000 spindle Speed rpm ite kD EOI rok 1827 4530 Options Coord s 200m Reset b 848799 Copy to Clipboard Add to Report Ctrl 4 Boring Drilling Print Printer Setup More Options Cbrl 0 Figure 1 3 8 Adding the simulation results to the Report 1 3 4 4 TOOLS U CutPro
31. Spindle speed rpm Axial Depth of Cut mm and etc as well as radial width of cut Note that some parameters are linked to each other and calculated automatically based on the others such as Spindle speed surface speed and Material removal rate W CutPro Untitled csf File Simulation Results Tools Window Help Des amp kA Mew Open Save Properties Run 7 gt lin Modal MalTF Mal Q SpindleProa Animation Plot All d Run Temp Machining ETNEA a E Process Cutting Conditions lt gt x ti iiti Mod Hide 4 o HUNG MOJE Back Mext Tabs Cancel Ok General Machine amp Tool workpiece Cutting Conditions Temperature Spindle direction Clockwise 0 Counterclockwise J Feedrate mmute 0 05 Spindle speed RPM FOOU Milling Mode Axial depth of cut al rom 5 C Donn miling Number of revolutions 10 i Up milling Sampling frequency scale 10 C Slatting Material removal ratel ermin 17 625 Face milling Surtace speed m min 299 237 Radial width of cut E mm 3 525 Milling Advanced Figure Cutting Conditions Prediction of cutting Milling Mode Other Parameters Figure 3 1 90 The Cutting Conditions Milling Mode tab Enter the feed rate of the cutting operation as mm tooth If the feed rate is in mm min use the following equation to convert feedrate mm min f h feedrate mm toot numberof flute i spindlespeed rev min If you h
32. Tabs Hide tabs Tabs Show Tabs Show tabs ries Cancel Cancel the simulation Cancel v Ok Save the simulation TK parameters CutPro starts with the Simulation Properties window of the 2 Axis Milling module by default You will be prompted to enter the necessary parameters for the selected process and can switch from one tab to another by clicking the Back or Next buttons on the MAL Inc User Manual for CutPro exe 32 Simulation Properties window You can hide or show tabs by using the Hide Tabs or Show Tabs button After you enter all the parameters you have to click the OK button to be able to save the process parameters you have defined and to run the simulation mode you chose If you click on the Cancel button you will lose the data you entered and cancel the simulation By clicking on the Run button on the Toolbar of CutPro you begin running your simulation There are six simulation modes single time domain Stability lobes in time domain single analytical stability lobes multiple analytical stability lobes optimize variable pitch cutting coefficient identification In this section each of them will be summarized step by step and you can find more details about the simulation properties window s tabs and definitions in Section 3 1 2 Axis Milling Module When you select a simulation mode the Sample Results window will give an example of the output figures for the specified simulation mode 2 1 1 1 MILLIN
33. Untitled csf File Simulation Results Tools Window Help Modal Analysis i New MalDA Run Run Temp Plot All Machining Pug Animation Process nar SpindleFro VirbualChc gt eee ba x SINL Linits p k Next Tabs Cancel C Gen Fl LETTURE pe Work piece Cutting Condi Figure 1 3 9 Tools menu in CutPro Ery MAL Inc User Manual for CutPro exe Table 1 3 5 The drop down menu of Tools command 25 Modal Analysis Run the Modal Analysis program Modal Analysis Run MalTF the transfer function measurement program MalDAQ Run MalDAQ the data acquisition and analysis program Milling Animation Run the Milling Animation program SpindlePro Run SpindlePro which is used to design and analyze the spindle systems VirtualCNC Run VCNC which simulates the performance related properties of Cartesian Configuration CNC machine tools before the actual machining process Units Choose to display units in CutPro in Metric or Imperial units of measurement Language Choose the language of CutPro The options are English German and French 1 3 4 5 WINDOW i CutPro Untitled csf File Simulation Results Tools window Help Close All 1 Cutting Forces Untitled csf 2 Cutting Force Untitled csF 3Y Cutting Force Untitled csF 4 Resultant Force in the Plane Untitled cst 5 Z Cutting Force Untitled csF 6 Tangential Cutting Force Untitled csF 8 7 Chip Thickness Untitled cs
34. a file by entering its name in the text box provided or by clicking the Browse button Click F and Bi to define other measurements in the same direction i e X11 X12 X13 MAL Inc User Manual for CutPro exe 200 6 3 2 MODAL MODEL You can select Complex Modes for non proportional damping or Real Modes for proportional damping Real Modes is sufficient to use in machining applications If you select Complex Modes the parameters file will contain residue values For the multiple transfer function measurements along the depth of cut Complex Modes must be selected If you select Real Modes the parameters file will contain mode shapes For one point transfer function measurement in any direction you can select both Modes Complex or Real Real Modes are recommended if you have only one measurement in one direction 6 3 3 FRF TYPE You can select Acceleration or Displacement sensor measurements CutPro does the conversions automatically 6 3 4 IMPACT POINT This is the point where you hit with the hammer 6 3 5 GAIN CONSTANT All measurements are multiplied by the Gain Constant It can be used to scale the sensor measurements if they have not already been scaled Example Transfer function measured using accelerometer and impact hammer with force sensor Accelerometer type is PCB 9690 Sensitivity is 5 17 mV g ms2 0 102g Hammer and force sensor type is PCB 7902 Sensitivity is 0 22 mV N with steel ti
35. amp Tool Structural Flexibility tab Apply Gain Constant i Existing file name Testh aFRFH_ rewa frf Gain constant to apply 1 000 Mew file name TestM atA Fs new new fri Browse Figure 3 1 65 Apply Gain Constant window You can exclude the dynamic effects of the direction you want on the structure by checking the box next to the Rigid option in the FRF Type frame in Machine amp Tool Structural Flexibility tab 3 1 5 2 2 MODAL RESIDUE DATA FILES When you select the Modal residue data files option in the Machine Dynamics Mode given by Figure 3 1 63 you can include the dynamic parameters of the machine and tool in the simulation by downloading the cmp files created in the Modal Analysis module of CutPro After a transfer function measurement the data is processed in the Modal Analysis module The Modal Analysis module fits a curve to the measurement and predicts the dynamic parameters If you wish you can save these parameters in a file named with cmp extension then load this file into CutPro by using the following frame that shows up with the choice of Modal residue data files option MAL Inc User Manual for CutPro exe 93 amp modalresidue file Rigid D Testi alos cmp Open Mew T modalresidue file Rigid D TestMaMady cmp Open New amp modal residue file Rigid T Testhd alloc crip Gpen Hew Figure 3 1 66 Downloading cmp files frame in Machine amp To
36. amp torque starting level oe I Spindle bending moment End level Drilling W Chip thickness After you have run the simulation you may view the miling animation by clicking the Animation button on the main toolbar Simulation Mode Output Figure 3 1 2 The General Output tab of the 2 Axis Milling module If you run the simulation modes one by one by using the default parameters in CutPro you will obtain the following output plots for each simulation mode After the simulation mode is chosen the results are obtained by first clicking on the OK button on the Simulation Properties window and then the Run button in the Toolbar In order to display results of the simulation click on the Plot All button on the Toolbar or click the drop down arrow on the Plot All button to select a single result to plot Please refer to Figure 2 1 1 in section 2 1 Milling Module for the definitions of the x y and Z axes 3 1 2 1 MILLING PROCESS SIMULATION In the General Output tab of the Milling Process Simulation mode you can save the cutting forces in x y z and tangential MAL Inc User Manual for CutPro exe 57 directions the resultant cutting force in xy plane the tool vibration in x and y directions the workpiece vibration in x and y directions the surface finish the spindle power and torque and the spindle bending moment at the first spindle bearing location based on the tool tip and chip thickness for each flute c on
37. automatically appear in the window You can enter the material name description and geometry and save the data as a user defined material 8 5 EXAMPLE D OBTAINING MAXIMUM TEMPERATURE ALONG CUTTER ROTATION This example illustrates how to run a temperature simulation to simulate the maximum temperature history along the cutter rotation The following steps are contained in the example file Ex13_Temperature_Milling csf A carbide 4 fluted cylindrical endmill with uniform pitch is used for this simulation The workpiece is Aluminum AL 075 T6 Select the Advanced Milling Module choose Single Time Domain MAL Inc User Manual for CutPro exe 251 Click Next to go to the General Output tab Select the files to be saved as text files during the simulation Also the revolution and level data can be entered in the Animation Options Click Next to go to the Machine amp Tool Cutter Type tab Select Cylindrical endmill with 4 flutes at uniform pitch Click Next to go to the Machine amp Tool Cutter Properties tab Select Carbide from the cutter material drop down menu Enter the appropriate parameters as indicated at the beginning of the example Click Next to go to the Machine amp Tool Structural Flexibility tab Select Dynamic vibrations for the Machine amp Tool Model and enter the dynamic parameters The natural frequencies are 500Hz and 7OOHz respectively in X and Y directions The damping ratio is 0 05 and the stiffness is 1
38. be linear e g 30 45 60 75 etc Sinusoidal angle Variation in the pitches is assumed to be sinusoidal The angle at which the simulation Starting angle starts scanning for the first pitch Chatter freg incr Increment in chatter frequency Pitch angle incr Increment in pitch angle MAL Inc User Manual for CutPro exe 126 3 1 9 3 CUTTING COEFFICIENT IDENTIFICATION 4 CutPro Untitled csf File Simulation Results Tools Window Help ioe H ws New Open Save Properties Run Lee Run Temp Plot ll 7 gt lin 4p Modal MalTF Malb4Q SpindlePra Animation Machining RUE Deir stadt Process Cutting Conditions ee lt gt Hide x v Ofner Parameters Back Next Tabs Cancel General Machine amp Tool workpiece ae Hillin T i 4 Cutting Coefficient Calculation Expenmental Cutting Forces File name 1 Average method ExpCutForce O50_ 2 bet c Geometrical average Browse Edit method Feed rate mmtlute 0 05 Back Delete Mest gt YS P Al Drilling Hilling Advanced Prediction of cutting forces Milling Mode Other Parameters Figure 3 1 99 Cutting Conditions Other Parameters in Cutting Coefficient I dentification simulation mode For this simulation mode you will load the measurement files one by one specifying the feed rates of each condition You can see the brief description of the buttons and methods in th
39. can define the tool geometry tool number tool manufacturer cutting type and you can select the cutting condition dry or lubricated NOTES Notes fe Figure 3 1 77 Notes frame in the Material Editor window You can write extra information about the material into the text box in Notes frame SAVE CANCEL Save Cancel Figure 3 1 78 Save and Cancel buttons tn the Material Editor window Press Save to save changes and exit the Material Editor window Press Cancel to exit Material Editor window without saving any changes 3 1 6 2 CUTTING COEFFICIENT MODEL On the Workpiece Material tab See Figure 3 1 69 you can select different cutting coefficient models for your simulation mode MAL Inc User Manual for CutPro exe 103 Average cutting coefficient Based on average force measurements This is the simplest model which requires the least expenmental measurement Varlable cutting coefficient Based on an average cutting coefficient model Cutting along the asial depth of cut coeficients are varying along the depth of cut Orthogonal to oblique Based on orthogonal cutting tests Extensive experimental tests cutting transformation must be conducted applicable to any cutter geometry Bicinear force Based on an average cutting coefficient model with two cutting coefficient regions some power of chip thickness S emi mechanistic The cutting coefficients are a function of two main coefficients and the ge
40. commands do not affect the level measurements contained in the first column of the run out table EXAMPLE The run out deviations of flutes has been measured for the following cutter MAL Inc User Manual for CutPro exe 76 Figure 3 1 37 A sample cutter with its run out parameters The run out deviations of flutes will be entered to the file as follows O x File Edit Units The unit of the run out values i Micrometer Level mm Flute 1 Flute 2 Flute 4 U 22 5 11 5 5 U 2 10 20 5 5 B 3 J25 15 5 2 B F 4 35 14 5 2 fA F 5 43 7 13 5 5 FA 4 Figure 3 1 38 The run out parameters entered for the sample cutter in Figure 3 1 37 MAL Inc User Manual for CutPro exe T1 3 1 4 MACHINE amp TOOL CUTTER PROPERTIES TAB W CutPro Untitled csf Fie Simulation Results Tools Window Help Plot all oe H Properties Run Modal MalTE M Mew Open Save Run Temp Machining EDGE Tit itsoa i Process pgachine amp Too lt gt x y l Hide Cutter P ropetes Back Next Tabs Cancel OK General Machine amp Tool Work piece Cutting Conditions Temperature Select a cutter material Carbide Delete Radius n mm 9 525 radius center Rrl mm 0 Length L mm a radius center Az mra 9 52 First bearing position mm 200 Corner radius A mrm 3525 Helix il E Flute m ih le 3525 raen e A a Rakel 5 pa Lead distance mm i
41. e A 161 Jo RE EPa a E E E 161 Dee PH OCHES gire aa E E E 161 53 350 CUTTING COEFFICIENTS aniacuecousanieoneaiesantnamss monsiues oes 161 FO FPT E vann uence aebaas action 162 5 4 PLOT eee err reer errr eee E Ter EEA 162 224 1 MILLING MODULE PLOUS iessensencsiritwnencemnieerenhienisnauens 162 S242 TURNING MODULE PLOTS rtomercersa cadoderannteeteonetnreuates 167 3 4 5 BORING MODULE PLO Sicsstnssctcthonnssverorameatueacstnenanees 178 5 SAVING RESULTS amp RESULTS FORMAT 187 5 1 SAVI NG CUTPRO SIMULATION FILES s 5 187 5 2 EXPORTING RESULTS sssssnsnnsnnnnsnnnnnnnnnnnnnnnnnnnnnnnnnnn 188 5 3 RESULIS FORMATI S cusuesecnewcstueesncuineesesiiseesteescccsines 188 5 3 1 FORCES IN X Y Z AND TANGENTIAL DIRECTIONS 188 5 3 2 TOOL VIBRATIONS IN X AND Y DIRECTIONS acca 189 5 3 3 WORKPIECE VIBRATIONS IN X AND Y DIRECTIONS 189 5324 UPMILLING SURFACE FINISH tesscisastonecurssonensexsntandnens 189 5 3 5 DOWNMILLING SURFACE FINISH accon 189 5 3 6 CHIP THICKNESS MIDDLE OF CUT eee 189 Sa SPLUNDEE PO WEN ronimine E E 190 5 3 8 SPINDLE BENDING MOMENT ccccceeee eee eee eee e eee e eee 190 5 3 9 TIME DOMAIN STABILITY LOBES cc cc ccecee eee e eee e ees 190 5 3 10 ANALYTICAL STABILITY LOBES x soassaesinavepemetnerssentuietee s 190 5 3 11 ANALYTICAL STABILITY LOBES VARIABLE PITCH 191 5 3 12 MULTIPLE ANALYTICAL STABILITY LOBES 44 191 Ssd OF EHMUM Cr ANGE Skit ccensninene
42. eneral Machine amp Tool workpiece Cutting Conditions Temperature f Static analysis Predicts static cutting forces Single Insert Analytical Use this mode to simulate stability lobes within a narrow stability lobes speed range Figure 2 3 2 The Static Analysis mode is selected in General tab of the Single Insert Boring module MAL Inc User Manual for CutPro exe 2 3 1 2 51 This mode predicts the static cutting forces in tangential radial and feed directions area of cut spindle power and torque and boring bar deflection The process is assumed to be static in this mode Sample results window of static analysis mode is displayed in the following figure x Cutting Forces Force N 4 ij BH 1U Time sec Boring Bar Radial Deflection ee 20 40 BO a 100 UCI ea aaa a aaa E a P001 X mm Figure 2 3 3 Sample Results window of Static Analysis mode SINGLE INSERT ANALYTICAL STABILITY LOBES 4 CutPro Untitled csf Fil Simulation Results Tools Window Help ow H New Open Save Properties w Plot all m Run Temp 7 gt Modal MalTF Single Insert Analytical i stability lobes l Boring Head Analutical stability lobes Machining Ltt Ln E ny TE E Process General x gt x v Simulation Made Hide Back Neck Tabs Cancel OK General Machine amp Tool workpiece Cutting Conditions Temperature Predicts static cutting forces U
43. example The damping ratios are 0 05 for both directions and the stiffness is 1e7N m for both directions Click Next to go to the Workpiece Material tab Select Aluminum AL356 T6 from the workpiece material drop menu Select Average cutting coefficient mode for the purpose of this example Click Next to go to the Workpiece Structural Flexibility tab In this example the workpiece is assumed to be rigid Click Next to go to the Cutting Conditions Milling Mode tab Select Clockwise as the spindle direction and enter the feed rate Click Next to go to the Cutting Conditions Other Parameters tab Enter the parameters indicating the offset and width of cut Upon click on a textbox of one of the parameters a red arrow will appear in the diagram indicating what the parameter represents For this example the Y start offset is 19 05mm Y end offset is 19 05mm Start width is 9 525mm End width is 9 525mm Workpiece width is 38 1mm and the step is 19 05mm If the parameters are changed the number of analytical simulation to perform may change as a result Click Next to go to the Temperature Properties tab We are not interested in the temperature simulation for this process Run the simulation Click Results gt Plot gt Stability Lobes Multiple Anal MAL Inc User Manual for CutPro exe 248 Stability Lobes Multiple Anal Ex06_MultipleAnalytical csf z Ioj x Stability Lobes Multiple Anal zi Offset mm
44. for CutPro exe 15 Monitoring real time data Displaying data in time or frequency domain Loading and analyzing any range of saved data Digital filtering options Land SPINDLEPRO SpindlePro is a specially designed program for the design and analysis of spindle systems It has two sub modules 1 2 7 1 EXPERT SPINDLE DESIGN SYSTEM ESDS This module is used for the initial design of spindles ESDS is based on the efficient utilization of past design experience the laws of machine design dynamics and metal cutting mechanics The expert system leads to automatic generation of spindle configuration which includes drive shaft motor type and size transmission mechanism between the motor and shaft bearing types and tool holder style The bearing locations are optimized under the constraints of chatter vibration free cutting conditions ESDS has the following features According to the cutting conditions such as tool geometry work piece material cutting speeds depth of cut etc the required torque power and maximum motor speed are automatically predicted Automatic selection of spindle and transmission type Allows selection of lubrication Optimizes bearing locations 1 2 7 2 SPINDLE ANALYSIS MODULE SpindlePro This module is a finite element software that is used for performance analysis and optimization of the spindles It allows analyzing the static and dynamic response of machine tool spindles The rota
45. for loss of business profits business interruption loss of business information and the like arising out of the use or inability to use the software even if MAL has been advised of the possibility of such damages MAL s liability to you for actual damages from any cause whatsoever and regardless of the form of the action whether in contract tort including negligence product liability or otherwise shall in no case exceed the invoiced amount paid for the right to use the software and the documentation Trademarks Pentium is a trademark of Intel Corporation Microsoft MS DOS are registered trademarks and Windows 3 x Windows 95 Windows NT are trademarks of Microsoft Corporation IBM and PC AT are registered trademarks of International Business Machines Corporation All other trademarks are trademarks or registered trademarks of their respective owners 2003 Manufacturing Automation Laboratories Inc All rights reserved 4a MAL Inc User Manual for CutPro exe L1 I NTRODUGCGTF FON wevsswedennisnaecumnenienisnidereneienemesnewesus 9 1 1 INSTALLING CUT PRO ssssssssnsnsnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 9 tlt INSTALLATION INSTRUCTIONS sscntueseocseascnendedenpemeneenmens 9 1 1 2 OLDER VERSION OF CUTPRO ALREADY INSTALLED 10 1 2 CUTPRO MODULES saiisensennciereneeewsn ere reae ene 10 todi ee Cee ee ee ee ee eee ee 10 eZee TURNING MODULE co anaaceretsaaneesucae secassanimesaacereenenn 12 LAO BORING MODULE se
46. history of the process in terms of forces in three directions torque power vibration and etc is displayed You also have an option to save any simulation result in an ASCII file in order to use it in other programs such as Matlab Excel etc See Figure 1 3 6 in Section 1 3 4 3 the Export Results window in the Results menu of CutPro for details The milling process simulation is very useful for detailed examination of nonlinear effects such as jumping out of the tool from the cut tool run out and also complex cutting tool geometry The benefits of this simulation mode are you can predict the cutting forces considering the dynamics of the tool and workpiece structure and see if the cutting forces are beyond the limit that the tool can carry you can check if the chatter vibrations are very drastic which can cause the tool to brake down very easily you can predict the required torque and power for the simulated process and then check these values with the maximum power and torque limits of your machine you can predict the chip thickness variation by using either the exact kinematics of chip generation or the approximated chip model you can display the tool and workpiece vibrations in the x and y directions you can predict the roughness of the surface finish by looking at the surface finish graph and see if it is within the acceptable tolerances This simulation mode is usually used in conjunction with other Simulation modes such as sta
47. in this version of CutPro MAL Inc User Manual for CutPro exe 146 3 3 9 TEMPERATURE TAB Simulation Properties Back ext Tabs Cancel OK gt field E vx Machine amp Tool Workpiece Wokpiece materiak Aluminum ALTOT5 T6 Cutter materiak Carbide t Divisions along chip thickness Ny 10 H Angular divisions on tool Np 10 H Angula mcrements Hil 5 Tolerance F ing tool Groowe width mm g h Wokpece diameter mm 19 05 Use Matlab to display temperature distibution j Werkpiece and contour plots Figure Postion of bool and Work pose Figure 3 3 8 Temperature Properties tab of the Turning Module This tab allows you to change the Simulation properties concerning Temperature Please refer to Section 3 1 10 TEMPERATURE PROPERTIES on page 127 for more details about these properties MAL Inc User Manual for CutPro exe 147 3 4 BORING MODULE 3 4 1 GENERAL SIMULATION MODE TAB Tabs Cancel OK Workpiece Cutting Conditions Temperature Predhcls sahe cuting lonce Use thet moda lo simulate ctabdity lobes walkin a nance peed aries Hi Subhra COSTE Dated on ne Fatal ard Feed cutie locc Figure 3 4 1 General Simulation mode of the Boring Module Static analysis is selected in this figure This tab allows you to choose the simulation mode There are two Simulation modes available Static Analysis and Analytical stability Solution The former predicts the cutting forces
48. magnification of the figure Reset Reset magnification of the figure Edit Opens the Spline Value Editor window and allows you to edit the current file Print Brings up a print dialog which allows you to print the figure at its current magnification Close Closes the figure window Flute Selects the flute number to see the serration profile In order to see the coordinates of the inputs red points in Serrated Cutter Spline window place the mouse pointer over the points and use the Ctrl key and left mouse button at the same time to zoom in a window 3 1 4 3 INDEXABLE CUTTER PARAMETERS For Indexable cutter geometry option under Machine amp Tool Cutter Type Machine amp Tool Cutter Properties tab has different options which are given in the following figure MAL Inc User Manual for CutPro exe 86 Indexable Cutter Parameters H Inserts on each flute 5 Current flute fi fi ka Current inzert Type Conver triangular 1 Edit insert type Copy across flutes Copy downn flute Copy to all positions Figure 3 1 55 Indexable Cutter Parameters on the Machine amp Tool Cutter Properties tab You can enter the number of inserts on each flute and define different insert types for each insert on the tool Rectangular and convex triangular inserts are the default insert types defined in CutPro Rectangular inserts are defined by width a and length b XYZ Cutter coordinate system uvw
49. oO 5000 10000 15000 20000 Spindle Speed rpm ei tS x 2D177E 04 Options Coord s Zoom Reset Y 0 321764 This plot displays the analytical stability lobes in the frequency domain MAL Inc User Manual for CutPro exe 187 5 SAVING RESULTS amp RESULTS FORMAT After a simulation is run the entire simulation can be saved in a csf CutPro Simulation File file Individual results can also be exported into text files in ASCII format The following is a description and instruction of saving csf files and exporting results 5 1 SAVING CUTPRO SIMULATION FILES Before or after a simulation is run the simulation can be saved ina csf file If the simulation has not been run only the properties of the simulation will be saved i e the tool material workpiece material cutting conditions etc If the simulation has been run already the simulation properties as well as the results will be saved in the csf file To save a simulation file simply click Save on the main window toolbar Save Or the file can be saved by clicking File gt Save If a simulation file is open and you wish to save it under a different name click File gt Save As and a Save Document window will appear Type in the desired file name and click Save MAL Inc User Manual for CutPro exe 188 Save Document x Save in E CutFro e f ef EJ __ Examples Help Program _ Securkey a alloy csF May Networ Save as ty
50. of Optimize Variable Pitch mode all the options are disabled CutPro automatically saves the sets of optimum pitch angles and their corresponding maximum depths of cuts allowed for a stable process in the cutting conditions specified ae Optimum ariable Pitch Untitled csf Optimum Variable Pitch E 5 q oO O aE ih First Pitch Angle w fel ROS Ms Bo y 14 034618 Options Coord s Zom Reset Pitches Y 26 204r r8 Figure 3 1 19 Optimum pitch angles Click the right button of the mouse at a point to see the pitch distribution 3 1 2 6 CUTTING COEFFICIENT I DENTI FI CATI ON In General Output tab of Cutting Coefficient Identification mode all the options are disabled CutPro automatically saves averages of the experimental cutting forces in x y and z directions with the corresponding feed rate values MAL Inc User Manual for CutPro exe 67 Exp Average Cutting Forces Untitled csf Exp Average Cutting Forces p qd oo aa o LL Feed Rate mm flute fel OS BS Cutting X 0 244533 Options Coord s zoom Reset Coef s 301 534596 Figure 3 1 20 Average of experimental cutting forces Syke MACHINE amp TOOL CUTTER TYPE TAB a CutPro Untitled csf I File Simulation Results Tools Window Help New Open Save Properties Run Run Temp Plot All Modal TET y Sn Machining RIDE LAT ian rot ata Process Machine amp Tool lt gt Cutte
51. or edit user defined materials the specifications of currently selected material in the Material Editor window Copy Create a copy of the currently selected material and display it in the Material Editor window Import Import a material from an existing cwm file Delete Delete the currently selected material This button is only enabled for user defined materials If you click on the New or View buttons the following Material Editor window pops up MAL Inc User Manual for CutPro exe 97 Material Editor a File Properties Materilname Noname OOS y y A Description P Composition P Cutting Properties Tool geometry Tool ra fr Tool manufacturer Po Cutting type Po Cutting condition f Dry Lubricated Cutting Coefficient Model f Average cutting coefficient Exponential chip thickness variable cutting coetticrent SEM Mechanistic along the anial depth of cut a an obligue cutting Sandvik materiale Bilinear force Show Equation Average cutting coetticient model Kpa Mmm Ke Nmr E KeNmn Kg Mm K N mm fe K aglNmn B Edit Equation High order mechantstic 2e He Oe Notes Save Cancel Figure 3 1 71 The Material Editor window for User Defined Materials You can define and edit only the parameters of user defined materials The following frames appear in the Material Editor window Properties C
52. revolutions a Sampling frequency scale gl was Drillin Cutting Conditions Other Parameters Figure 3 4 7 Cutting Conditions tab This tab allows you to change the cutting conditions in the boring process such as feed rate surface speed spindle speed diameter of the hole etc amp Note Only Feed rate and Diameter of the hole can be modified in Analytical Stability Simulation amp Note Number of revolutions and sampling frequency scale cannot be modified 3 4 8 CUTTING CONDITIONS OTHER PARAMETERS TAB There are currently no other parameters that can be modified in this version of CutPro 3 4 9 TEMPERATURE TAB Temperature simulation is being developed MAL Inc User Manual for CutPro exe 155 3 5 TEMPERATURE PREDICTION The importance of temperature prediction for machining processes has been well recognized in the machining research community primarily due to its effects on tool wear and its constraints on productivity The rate of wear in particular is greatly dependent on the tool chip interface temperature Temperature is a major concern in the machining and production of advanced materials such as titanium and nickel based alloys As well as chatter Stability it is perhaps the main limitation in the selection of process parameters such as cutting speed and feed rate Due to the low thermal conductivity of these materials most of the heat generated during machining flows into the tool resulti
53. s Zoom Reset 13764876 Figure 3 1 16 Stability lobes in time domain 3 1 2 3 SI NGLE ANALYTI CAL STABILITY LOBES In the General Output tab of the Single Analytical Stability Lobes mode you can save complete results the analytical Stability lobes data which includes axial depth of cut and spindle speed values corresponding to the critically stable state of the milling process MAL Inc User Manual for CutPro exe 65 Stability Lobes Analytical Untitled csf Stability Lobes Analytical 5 yu o CL ci O 10000 20000 30000 40000 SQ000 BOOO0 Spindle Speed rpm je fel wes Options Coord s zoom Reset Figure 3 1 17 Single analytical stability lobes 3 1 2 4 MULTIPLE ANALYTICAL STABILITY LOBES In General Output tab of Multiple Analytical Stability Lobes mode all the options are disabled CutPro automatically saves the analytical stability lobes data which includes axial depth of cut and spindle speed values correspond to critically stable state of the multi step milling process se Stability Lobes Multiple Anal Untitled csf Stability Lobes Multiple Anal Offset mm Depth of Cut mm 1667 3333 S000 GGT EEEE 10000 Spindle Speed rpm A aD EO WS x 9663 692174 Options Coords Zoom Reset Y 12 175654 Figure 3 1 18 Multiple analytical stability lobes MAL Inc User Manual for CutPro exe 66 Sakaki OPTIMIZE VARIABLE PITCH In General Output tab
54. to go to the Cutting Conditions Milling Mode tab Select Clockwise and Downmilling for the spindle direction and milling mode Enter 9 525mm as the radial depth of cut as the process is half emersion Click Next to go to the Cutting Conditons Other Parameters tab No other parameters can be entered Click Next to go to the Temperature Properties tab We are not interested in the temperature simulation for this process Click OK Click Run on the main window toolbar to run the simulation this will take a minute or two depending on the speed of the computer MAL Inc User Manual for CutPro exe 239 Click Results gt Plot gt Stability Lobes Analytical Stability Lobes Analytical Complete Simulation Results Ex01 Si oj x Stability Lobes Analytical J l l l 5 6 f Depth of Cut mm 5 2426 2 4643 4 6560 5 See 11294 4 Spindle Speed rpm ee Eg ati tA Mf 2278 3583 Options Coord s zoom Reset Show All Y 200923998 Figure 9 8 2 2 Stability Lobes result As the graph indicates at 6000RPM and and axial depth of cut of 7mm the point is above the stability lobes hence the process is unstable Whereas at 8000RPM and 7mm depth of cut the process is stable In some circumstances you may choose to run the process at 8000RPM to ensure stability However for the purpose of this example it is supposed that a spindle speed of 8000RPM is not allowed What you can do i
55. 11E 01 4 3178E 02 3 3500E 02 3 2500E 02 3 3500E 02 3 2500E 02 5 3 12 MULTIPLE ANALYTICAL STABILITY LOBES The first column is y offset value between tool center and workpiece center mm The second column is spindle speed rev min The third column is axial dept of cut limit mm Example 1 9050E 01 2 2500E 02 1 7099E 01 1 9050E 01 2 4000E 02 8 5334E 00 1 9050E 01 2 5500E 02 6 9170E 00 5 3 13 OPTIMUM PITCH ANGLES The first column is axial depth of cut limit mm The second column is phase shift for flute number 1 deg The third column is phase shift for flute number 2 deg The fourth column is phase shift for flute number 3 deg The fifth column is phase shift for flute number 4 deg MAL Inc User Manual for CutPro exe 192 The number of column will be change with number of flute Example 3 0508E 01 9 0000E 00 1 7100E 02 9 0000E 00 1 7100E 02 2 9523E 01 1 0000E 01 1 7000E 02 1 0000E 01 1 7000E 02 2 873E 01 1 1000E 01 1 6900E 02 1 1000E 01 1 6900E 02 5 3 14 EXPERIMENTAL AVERAGE CUTTING FORCES The first column is feed rate mm tooth The second column is experimental Fx average force N The third column is experimental Fy average force N The fourth column is experimental Fz average force N Example 5 0000E 02 1 0380E 02 1 4642E 02 5 1815E 01 7 5000E 02 1 1600E 02 1 8847E 02 7 0230E 01 1 0000E 01 1 2112E 02 2 4060E 02 8 2586E 01 MAL Inc User Manual for CutPro exe 193 6 MODAL ANALYSIS CutPro
56. 12 Ex12_SingleAnalytical_MaWp csf Single Analytical Simulation for Regular pitch cutter with Machine and Workpiece dynamics This is a stability lobe simulation for cylindrical end mill 8 1 13 Ex13_Temperature_Milling csf Temperature simulation for milling with default cutting conditions 8 2 EXAMPLE A SIMULATING A DESIRED MI LLI NG PROCESS This example illustrates how to ensure the stability of a milling process at a particular spindle speed and depth of cut as well as using Optimize Variable Pitch to achieve a stable process with the desired cutting conditions if they are found to be unstable with a uniform endmill In this example a uniform Carbide cylindrical endmill of 32mm length is used for down milling AL356 T6 at a radial depth of cut of 9 525mm The spindle is clockwise and the feed rate is 0 05 mm flute The helix angle of the tool is 30 and the rake and relief angles are both 0 Suppose you wish to run the process at 6000RPM and an axial depth of cut of 7mm You would first obtain the stability lobes to check if the conditions are stable In this example these conditions are not stable with a uniform pitch endmill You can then find the optimal variable pitch to shift the stability lobes to ensure the process is stable at 6000RPM at 7mm axial depth of cut The details are contained in the simulation files Exi to Ex5 See Section 8 1 MAL Inc User Manual for CutPro exe 231 8 2 1 OBTAINING THE STABILITY L
57. 31 8303 84 3 657937 336 iF Wave Length 3 657937 336 Wave Amplitude 0 258594257 Figure 3 1 53 The Spline Editor window with example parameters entered Once the parameters are defined CutPro fits a spline to the given coordinates Please note that the serrations on the other flutes are defined with 360 N shifts in axial direction where N is the number of the flutes on the tool After you finish defining or editing the parameters save the file by clicking Save in the drop down menu of File command in Spline Value Editor window and then click OK in the The Spline File window window in order to use the file in the simulation When you click OK in the The Spline File window window Serrated Cutter Spline window pops up showing the profile of the serration and you can close this window afterwards MAL Inc User Manual for CutPro exe 85 aW Serrated Cutter Spline Radial Offset mm Outer radius of the tool 0 nm U 0 9 1 6 et 3 6 4 5 F 4d b d Along the flute To see the coordinates of the input points in red place the mouse pointer over the points Use the Ctrl key to zoom in a window a oom Ir oom Lut Heset Edit Print Flute 1 j Figure 3 1 54 Serrated Cutter Spline You can also open the Serrated Cutter Spline window by clicking on View button in Figure 3 1 46 Table 3 1 122 Buttons on Serrated Cutter Spline window Zoom In Increase magnification of the figure Zoom Out Decrease
58. 6 9 1 INTRODUCTION Receptance coupling is a method to acquire the assembled Frequency Response Function or receptance or compliance at the tool tip The assembled FRF information can be used to predict chatter vibrations Typically the spindle dynamics do not change over the time this should be checked regularly for preventive maintenance purpose but the tool dynamics change whenever a new tool is inserted into a tool holder This tool dynamics can be predicted by a FEM Finite Element Method to accurately come up MAL Inc User Manual for CutPro exe 211 with the tool dynamics This requires material properties and the tool geometries 6 22 ADVANTAGES The typical practice in shops to acquire predictions of FRFs is to measure the FRFs of each end mill used in the shop using impact modal tests with an instrumented piezoelectric force hammer and a vibration sensor The Receptance Coupling technique allows coupling of analytical or experimental FRFs of the components in obtaining the response of the assembly This eliminates the time consuming and repetitive FRF tests for each tool 6 9 3 FUNCTIONS OF THE SOFTWARE There are three sections in the Receptance Coupling Software 1 Tool Coupling Enables the identification of tool holder spindle assembly on the machine tool and coupling of tools to the tool holder 2 Coupling of Holder and Tool Assembly to Spindle Enables the identification of the spindle on the machine tool an
59. 6 9 15 Sample Receptance Coupling at Tooltip on an arbitrary tool displayed in Modal Analysis Press Exit to go to the main menu 6 9 4 5 LOADING EXISTING TOOL HOLDER SPINDLE ASSEMBLIES Press Load Existing Tool Holder Spindle Tool Coupling C Identify ToolHolderfspindle Assembly Load Existing ToolHolder Spindle Figure 6 9 16 Tool Coupling Load Existing Project MAL Inc User Manual for CutPro exe 224 Browse for existing tool holder spindle projects rcf files and open the existing spindle tool holder assembly Recent Desktop May Documents My Computer 3 My Network File name x Places Files of type Receptance Coupling Files rcf Cancel Figure 6 9 17 Tool Coupling Opening an existed project file Couple a tool to the tool holder as explained in 1 1 1 1 6 23 COUPLING OF HOLDER AND TOOL ASSEMBLY TO SPINDLE 6 9 5 1 EXPERIMENTAL PROCEDURE TO IDENTIFY THE SPINDLE HOLDER CONNECTION 6 9 5 1 1 APPARATUS It is recommended to use a shrink fit tool holder without any tool to perform the experiments for the identification of the spindle holder connection 6 9 5 1 2 EXPERIMENTAL PROCEDURE Insert the shrink fit tool holder into the spindle Attach an accelerometer on the holder shank and apply the impact hammer to MAL Inc User Manual for CutPro exe 222 acquire the frequency response functions Perform at least 5 10 impact tests to average FRFs Three impact hammer tests
60. AL Inc User Manual for CutPro exe 106 H CutPro Untitled csf Fie Simulation Results Tools Window Help D ee 7 Open Save Properties Run Run Temp MalDaAQ SpindlePro VirtualcNc Anime Machining BST bit meet edt Process Cutting Conditions lt gt mal yY ther Parameters Back Next Tabs Cancel OK General Machine amp Tool Workpiece Cutting Conditions Temperature Cutting Coefficient Calculation Experimental Cutting Forces File name H i Average method S5000_ 02 F0125 mdg Geomettical average Browse method Feed rate rom flutel lt Back Delete Next gt Drilling Miling Mode Other Parameters Opened fle C CutPro Program default cst as Untitled cst Make sure to enter the corresponding correct feed per tooth Than push next gt and select the next file and corresponding feed Make sure that the files start with the smallest feed and increases without mixing the sequence Once you finish loading you need to go back and check whether all the files and feeds are entered correctly Click the next button after you complete the file entry 4 If you click on OK and run CUTPRO will create a temporary material data Click on Plot all and you will see a graph with average measured cutting forces If they form a linear trend the prediction will be good Otherwise the cutting coefficients may be sensitive to the insert geometry and chip load If you click on
61. AL Inc User Manual for CutPro exe 257 9 5 2 Geometry type Ball End D 0 R R 40 R 0 a 0 B 0 h 0 Tangent Radius D 0 R40 R 0 R 0 a0 B 0 h0 General End D 0 R40 R40 R20 a0 0 h 0 MAL Inc User Manual for CutPro exe 258 Flute type figure Ss Pee Constant helix Constant lead MAL Inc User Manual for CutPro exe 9 5 4 Cutter amp Insert Coordinate Systems XYZ Cutter coordinate system uvw Insert coordinate system Z MAL Inc User Manual for CutPro exe 259 Lead Angle 6 Z Cutting edge uw MAL Inc User Manual for CutPro exe 260 Lag Angle o Y Cutting edge uw MAL Inc User Manual for CutPro exe 261 262 10 Appendix B 10 dFt dFr dFa dS dz chip thickness mm gt 1 Appendix B1 Orthogonal to oblique cutting transformation model Equations dF K dS K h dz dF K dS K h dz dF K dS K h dz tT cos f a tan7 sin 2 tani tc sin D C T sin f amp rce a sin cosi C T cos f a tani tan7 sin ff sin D C ac c cos B a tan 7 sin p differential tangential force N differential radial force N differential axial force N differential cutting edge length mm differential axial depth of cut mm shear stress N mm2 Shear angle friction angle rake angle chip flow angle helix angle t
62. B 144 3 3 7 CUTTING CONDITIONS TAB 1 ccc cece eee neers 145 3 3 8 CUTTING CONDITIONS OTHER PARAMETERS 4 145 22000 TEMPERATURE TAD regerme nern E A ES 146 3 4 BORING MODULE cccccccccccecccceeeeeeeeeeeeeeeeeeeeeeennnees 147 3 4 1 GENERAL SIMULATION MODE TAB ccccceceee cess sense ees 147 3 4 2 GENERAL OUTPUR TAB vcs seeseesemcimaamssrasmenamtetmagennenan 147 3 4 3 MACHINE amp TOOL TOOL PROPERTIES TAB 065 149 3 4 4 MACHINE amp TOOL STRUCTURAL FLEXIBILITY TAB 151 3 4 5 WORKPIECE MATERIAL TAB ccc cece cece rere eee e ee eeeeeees 152 3 4 6 WORKPIECE STRUCTURAL FLEXIBILITY TAB 153 24 7 CUTTING CONDITIONS TAB ssivaictasancvnnstasnncdoaptartanaset 154 3 4 8 CUTTING CONDITIONS OTHER PARAMETERS TAB 154 3 49 TEMPERAFURE TAD errorae EEE 154 3 5 TEMPERATURE PREDICTION sssssssnnsnnnnnnnnnnnnnnnnnnnnnnn 155 MAL Inc User Manual for CutPro exe 4 RUNNING A SIMULATION nssssnnnnnsnnnnnnnnnnnnnnnnnnnnn 157 4 1 RUNNING A MACHINING SIMULATION cccccsseeee 157 4 2 RUNNING A TEMPERATURE SIMULATION 157 gt VIEWING RESULSS siisciecerereseeenitecieseresesmenssctewenss 159 5 1 VIEWING ALL RESULTS cc ccccccccccceeeeeeeeeeneeeeeeeeeeeees 159 5 2 VIEWING INDIVIDUAL RESULTS ccssssseeeeeeeees 159 5 3 RESULTS WINDOW ccccccccccceeeeeeeeeeeneeeeeeeeeeeeeeenenees 160 Saded OPON ae 160 Po A I OC OJRDINATE S iae s 161 o LOOM eea E
63. Bring up the standard Windows Printer Setup dialog Setup which allows you to select a printer and change print options such as paper size Copy Plot Copies the graph onto the clipboard as a bitmap to save as a file click paste on a picture editing software Exit Exit modal analysis Modes Add Mode Add the currently selected mode Delete Delete the mode currently selected in the Modes Mode Table Plot Plot the currently defined modes without Modes optimization See Defining and optimizing modes in Section 6 5 for more details Display Display the Modal Matrix in a new window Modal Matrix Optimize Optimize the currently defined modes See Defining and optimizing modes in Section 6 5 for more details Results Report Display the summary of simulation conditions Options Units Change units between metric and imperial Language Change language among English French and German Tools Receptive Open the Receptive Coupling window Please see Coupling Section 6 9 RECEPTANCE COUPLING for more details MAL Inc User Manual for CutPro exe 195 6 2 MODAL ANALYSIS WINDOW TOOLBAR BUTTONS Gaz ak TOP TOOLBAR 6 2 1 1 OPEN as Same function as File gt Open Please see Section 6 1 3D MODAL ANALYSIS MENU 6 2 1 2 SAVE bar Same function as File gt Save Please see Section 6 1 3D MODAL ANALYSIS MENU 6 2 1 3 SELECT FRF FILES ah LA Same function as File gt Select FRF Files Please see Section 6 1 3D MODAL ANALYSI
64. CutPro CutPro exe User Manual manufacturing automation laboratories 4a MAL Inc User Manual for CutPro exe 2829 Highbury Street Vancouver B C V6R 3T7 Canada Tel 604 228 9213 Fax 604 228 9269 E mail sales malinc com URL http www malinc com This document is a work in progress If you find any errors or omissions please bring them to the attention of The Manufacturing Automation Laboratory at the University of British Columbia Important Notice Manufacturing Automation Laboratories Inc MAL reserves the right to modify or discontinue the software or the software specification identified in this document without notice MAL advises its customers to obtain the latest version of the software specifications to verify before placing orders that the information being relied upon by the customer is current MAL makes no warranties expressed or implied including without limitation the implied warranties of merchantability and fitness for a particular purpose regarding the software MAL does not warrant guarantee or make any representations regarding the use or the results of the use of the software in terms of its correctness accuracy reliability currentness or otherwise You assume the entire risk as to the results and performance of the software In no event will MAL and its directors officers employees or agents be liable to you for any consequential incidental or indirect damages including damages
65. Cutting Coefficients button on the graph s bottom menu you will see the parameters as shown below You can edit material and other fields as you wish except for the coefficients which are identified by CUTPRO for you Once you push the save button you will have user specific material data in the CUTPRO which can be accessed only by you MAL Inc User Manual for CutPro exe 107 n CutPro Untitled csf File Simulation Results Tools Window Help O lay of i ae X 2 New Open Save Properties Run Run Temp Plot All Modal MalTF MaIDAQ SpindlePro YirtualCNC Animation Machining Process Material Editor File Description Average miling cutting coefficients Composition Cutting Coefficient Model Cutting Properties Properties Material name Average milling cutting coefficients Y Average cutting coefficient c Variable cutting coefficient Semi mechanistic Tool geometry alona the axial depth oF cut Hig vorder mechanistic Tool no O Orthogonal to oblique cutting PTs PERO eRe S Astmaan sandvik materials Tool manufacturer C Bilinear force Show Equation Cutting type r Average cutting coefficient model Kie N mm 29 78 K e Nmn 678 108 Ke N mm 23 513 K pe N mn 222 102 Sa K gelN mm 4 311 K oN mm 240 243 Edit Equation Save Cancel i AT j ene p Drilling Cutting condition Dry C Lubricated 3 1 6 2 1 AVERAGE CUTT
66. Editor window which shows up when you click on the Edit Equation button in Figure 3 1 73 allows you to define cutting coefficient model parameters by using equations ten tet eal acot cath logi a_t rad Cancel Figure 3 1 75 One of the parameters is represented with an equation in Equation Editor window as an example You enter the equations for the cutting coefficient model parameters by clicking on the buttons in the Equation Editor window The following mathematical functions are available in Equation Editor window See Figure 3 1 75 Table 3 1 188 Mathematical functions in the Equation Editor window sin Sine COS Cosine tan Tangent sec Secant CSC Cosecant cot Cotangent asin Arcsine acos Arccosine atan Arctangent asec Arcsecant ACSC Arccosecant acot Arccotangent sinh hyperbolic sine cosh hyperbolic cosine tanh hyperbolic tangent sech hyperbolic secant csch hyperbolic cosecant coth hyperbolic cotangent exp et the inverse of In e 2 71828182845904 In natural logarithm logio base 10 logarithm sqrt Square root MAL Inc User Manual for CutPro exe 101 amp All mathematical functions must be followed by an argument written in parentheses The following cutting parameters are available in the Equation Editor window See Figure 3 1 75 Table 3 1 19 Cutting parameters in the Equation Editor window h chip thickness mm Z depth of cut mm i local heli
67. G PROCESS SIMULATION CutPro Untitled csf File Simulation Results Tools Window Help et Od A Mew Open Save Properties Run Run Temp Modal MalTF M Machining EEE Sed EE Process General Simulation Mod gt e s v PU AUO AMANO Ge Mex Tabs Cancel OK General Machine amp Tool workpiece Cutting Conditions Temperature m Single analytical A fast analytical stability lobes prediction solved in a frequency stability lobes domain Tusnin z Milling process Simulates cutting forces tool vibrations surface finish spindle 2 simulation power and spindle bending moment imn a single time domain Figure 2 1 4 Milling Process Simulation mode is selected in General tab of the 2 Axis Milling module MAL Inc User Manual for CutPro exe 33 In this simulation mode cutting forces in x y z and tangential directions resultant cutting force in xy plane chip thickness tool vibration and deflection workpiece vibrations surface finish due to forced and chatter vibrations spindle power and torque bending moment acting on the machine tool and animation of chip removal are simulated based on the cutter geometry machining parameters and dynamic modal parameters of both the workpiece and tool defined by you In this time domain simulation the process is simulated based on numerical integration algorithm for the defined condition and parameters with small time increments At the end of the Simulation the time
68. ING COEFFICIENT The average cutting coefficient model is based on average force measurements This is the simplest model which requires the least number of experimental measurements You can use this model for a specific material and cutting tool geometry In the following figure you can see the Average cutting coefficient model frame in Material Editor window Average cutting coefficient model Kee N mm Kee N m K Nim Ky INA k gel mm K ag lN mr Edit Equation Figure 3 1 80 Average cutting coefficient model frame The following parameters are used in order to define average cutting coefficient model MAL Inc User Manual for CutPro exe 108 Table 3 1 201 Parameters for Average Cutting Coefficient model Kte Tangential edge force coefficient N mm Kre Radial edge force coefficient N mm Kae Axial edge force coefficient N mm Ktc Tangential shearing coefficient N mm Krc Radial shearing coefficient N mm Kac Axial shearing coefficient N mm VARIABLE CUTTING COEFFICIENT ALONG THE AXIAL DEPTH OF CUT This force model is based on the Average Cutting Coefficient model except the cutting coefficients vary along the axial depth of cut In the following figure you can see the Variable cutting coefficient along the axial depth of cut model frame in Material Editor window Vanable cutting coefficient along the axial depth of cut K N mm Ke Nmr Ke i Kre Nr K Nm K lM Arne
69. MAL Inc Display information about CutPro Visit website http www malinc com Send your questions to MAL Inc MAL Inc User Manual for CutPro exe 21 4 CutPro Untitled cst File Simulation Results Tools Window Help Help Topics CutPro 6 0 ajx Contents Index Fina Click a topic and then click Display Or click another tab such as Index Introduction What s Hew Installing CutPro Getting Started with CutPro Overview of CutPro Activating Modules Exporting Results Running a Simulation Example Files Milling Animation Uninstalling CutPra ES E3 E3 ES ES Es E3 ES ES bs bs es Support g Properties ga Viewing Results 30 Modal Analysis Print Cancel Figure 1 3 12 Help menu in CutPro Contents and Index window Contents option w CutPro Untitled csf File Simulation Results Tools Window Help Help Topics CutPro 6 0 x Contents Index Find 1 Type the first few letters of the word you re looking For 2 Click the index entry you want and then click Display Activating Modules Average cutting coefficient model Equations Average cutting coefficient model Maternal editor Ball end endmill Bilinear force model Equations Bilinear force model Material editor Chip thickness Coefficient maternal model tab Contacts Cutter material Cutting coefficient identification Cutting coetficient model equations Cutting coefficient model par
70. MAND MAL Inc User Manual for CutPro exe 83 i Spline Yalue Editor lOl x File Edit Units Help Slope of cur w Milimeters Ctrl M Micrometers Ctrl U Slope of cur ave Length w ave Amplitude Figure 3 1 51 Units command on the Spline Value Editor window Table 3 1 11 The drop down menu of Units command on Spline Value Editor window Millimeters Display all measurements in millimeters mm Micrometers Display all measurements in micrometers um HELP COMMAND w Spline Yalue Fdiknr File Edit Unit Help Slope of curve at the Start Pom BE E Slope of curve at the End Point BC2 E ave Length iw ave Amplitude Figure 3 1 52 Help command on the Spine Value Editor window is highlighted by red box MAL Inc User Manual for CutPro exe iw Spline Editor C CutPro Program s File Edit Units Help 5 x Slope of curve at the Start Point BCT jo Slope of curve at the End Point BC2I fo 2 5 4 a B T E a mm 0 0 1797 304355 0 356521 753 0 495652 0 769249532 1 050658577 1 7 72194657 1 565079878 1 953074663 2 Uzer 2927 2 102709452 2 feeb Ib41 3 2 413919898 2 546090338 2 02608605 2 043495566 3043718183 325160659 0 0 007891 8 0 017 7135387 0 034011414 0 064457 646 0 135016236 027232044 O 26497211 0 200094257 0 206271 353 0 2 78856304 0 2531 271566 0 1 8985375 0 1292689 76 O 080429034 0 052946 94 0 0326 79264 0 009
71. MENT The first column is time sec The second column is instantaneous bending moment Nm The third column is cumulative average bending moment Nm Example 0 0000E 00 1 0132E 01 1 0132E 01 1 2500E 04 1 0232E 01 1 0182E 01 2 5000E 04 2 1073E 01 1 4736E 01 5 3 9 TIME DOMAIN STABILITY LOBES The first column is spindle speed rev min The second column is axial depth of cut mm Example 2 0000E 03 3 4768E 00 2 1000E 03 1 4742E 01 2 2000E 03 1 0761E 01 5 3 10 ANALYTICAL STABILITY LOBES The first column is spindle speed rev min The second column is axial dept of cut limit mm MAL Inc User Manual for CutPro exe 191 The third column is chatter frequency Hz Example 2 2500E 02 1 7099E 01 4 4815E 02 2 3000E 02 1 3297E 01 4 5767E 02 2 3500E 02 1 0492E 01 4 6707E 02 Duet ANALYTICAL STABILITY LOBES VARIABLE PITCH The first column is spindle speed rev min The second column is axial dept of cut limit mm The third column is chatter frequency Hz The fourth column is phase shift for flute number 1 deg The fifth column is phase shift for flute number 2 deg The sixth column is phase shift for flute number 3 deg The seventh column is phase shift for flute number 4 deg The number of columns will change with the number of flutes Example 1 0947E 03 2 511E 01 4 3178E 02 3 3500E 02 3 2500E 02 3 3500E 02 3 2500E 02 5 4350E 02 2 511E 01 4 3178E 02 3 3500E 02 3 2500E 02 3 3500E 02 3 2500E 02 3 6149E 02 2 5
72. N A MULTIPLE STEPS PROCESS This example illustrates how to obtain the stability lobes for a process with different steps In this example three steps are performed in the process half emersion down milling full emersion milling and half emersion up milling AY Figure Multiple analytical stability lobes A carbide cylindrical endmill with 4 flutes at uniform pitch is used for this process The tool has radius 9 525mm helix angle of 30 relief and rake angles of 0 The workpiece is Aluminum AL356 T6 and is rigid The feed rate is 0 05mm flute and the spindle direction is clockwise The following steps are contained in the example file Ex06_MultipleAnalytical csf Select the Advanced Milling module Select Multiple analytical stability lobes Click Next to go to the General Output tab Note that no selection can be made on this tab Click Next to go to the Machine amp Tool Cutter Type tab Select Cylindrical end with 4 flutes at Uniform pitch Click Next to go to the Machine amp Tool Cutter Properties tab Select Carbide as the cutter material Enter the radius Helix Relief and Rake angles of the tool Click Next to go to the Machine amp Tool Structural Flexibility Select Dynamic vibrations for the Machine amp Tool Model Enter the Dynamic Parameters select it first The natural frequencies are respectively 500Hz and 700Hz in the X and Y direction for this MAL Inc User Manual for CutPro exe 247
73. OBES First you can obtain the stability lobes for the desired process and check if the cutting conditions will be stable The following steps and details are all contained in the example file EX01_SingleAnalytical csf To do this select the Advanced Milling Module and choose the Single Analytical Stability Lobes mode Machining ESTE iat e ete j Process Gewora i en ee lt gt fied v seme wirufation Mode bak Net Tabs Camel O General Machine amp Tool Workpiece Cutting Conditions Temperature A Taa E _ Simulates cutting forces tool vibrabons surface finish spindle Single bme domat cower and spindle bending moment in a single time domain c Stability lobes in tme Use this mode to simulate stabilty lobes within a nanow speed range domain for a complicated cutter Othervise see below G Single analtical 4 fast analytical stability lobes prediction solved in a frequency jstabiity lobes j domain co Muliple analytical Generates stabilty lobes with axial and redial depths of cwt and stability lobes spindle speed c Optimize vanable Aulomatically calculates pitch distibution at a specie spindle pich speed for a grven number of Aubes e Cutting coeflicsent Automatically idenbhes the cutting coeficients based on files identification defining lt Y and 2 cuthing forces Simulation Mode Figure 9 8 2 1 Select Single Analytical Stability Lobes in the General Simulation Mode tab Click Next t
74. Pro exe 104 Presently you need to conduct the cutting tests using a slotting procedure Make sure that there is no chatter when you conduct the cutting tests otherwise the dynamometer will not measure the forces correctly due to its limited bandwidth Typical cutting force data for a 2 fluted end mill is shown here which is saved as S5000_D7_f0125 mdq binary file About 5 6 cutting tests with a feed range starting from 0 05 to 0 075 0 1 0 125 0 150 0 200 mm tooth should be sufficient Manta 5000_D FO125 mdq File Edit Measurement View Help eh SeES Aas OB Upper Graph 00 j Channel 0 100 Filter 200 ja 22 5 22 65 22 9 22 95 23 x 2 29053e 001 VY 2 24609e 002 dx 0 00000e 000 dv 0 00000e 000 400 Lower Graph m Aaaah __ Fei ATTN 200 D a a E x 2 28002e 001 Y 1 39160e 002 dx 0 00000e 000 dY 0 00000e 000 EEA ee For Help press F1 SR 10 kHz SW 0 24 s Not Logging After collecting the cutting force data please follow the procedure given below 1 Select Cutting Coefficient Identification option from Simulation Properties window To upload measured cutting force data select Browse under Cutting Conditions tab Enter the number of teeth in tool geometry menu and make sure to click on rigid for both cutter and part structure pages You can identify whether the tool material but it is not essential The tool mater
75. Rigid E M lt Previous Delete Insert Next gt Measured tf file Drilling f Dynamic parameters Cutter Type Cutter Properties Structural Flexibility Figure 3 1 60 Machine amp Tool Structural Flexibility tab Machine amp Tool Structural Flexibility tab allows you to enter machine amp tool dynamic parameters In this tab you have different parameters to define for your different selections MAL Inc User Manual for CutPro exe 90 3 1 5 1 MACHI NE amp TOOL MODEL You can model the machine amp tool in three different ways You can assume that during the process machine amp tool is rigid or dynamic vibrations occur in the system or machine amp tool deflect statically Machine amp Tool Model Rigid f Dynamic vibrations Static deflections Figure 3 1 61 Machine amp Tool Model in Machine amp Tool Structural Flexibility tab The choice of Rigid option in Machine amp Tool Model brings up the following frame Chip Model Exact kinematics C Approximation The chip model here is appled under both the Machine Cutter and the Workpiece tabs Figure 3 1 62 Chip Model frame In Chip Model frame you can model the chip by using either the Exact Kinematics option or the Approximation option For the Exact Kinematics option the exact kinematics of the process is considered therefore the simulation time can be longer In Approximation option chip thickness is modeled a
76. S MENU 6 2 1 4 SAVE MODAL PARAMETERS eA Same function as File gt Save Parameters Please see Section 6 1 3D MODAL ANALYSIS MENU 6 2 1 5 ADD MODE Same function as Modes gt Add Mode Please see Section 6 1 3D MODAL ANALYSIS MENU 6 2 1 6 DELETE MODE a i Same function as Modes gt Delete Mode Please see Section 6 1 3D MODAL ANALYSIS MENU MAL Inc User Manual for CutPro exe 196 6 2 1 7 PLOT MODES M Same function as Modes gt Plot Modes Please see Section 6 1 3D MODAL ANALYSIS MENU 6 2 1 8 OPTI MI ZE NATURAL FREQUENCY O Select this button if you wish to optimize the natural frequency 6 2 1 9 OPTI MI ZE DAMPI NG RATIO C Select this button if you wish to optimize the damping ratio 6 2 1 10 OPTIMIZE RESIDUES R Select this button if you wish to optimize the residues 6 2 1 11 PERFORM OPTIMIZATION H Wi Same function as Modes gt Optimize Please see Section 6 1 3D MODAL ANALYSIS MENU SHOW PREVIOUS MEASUREMENT 6 2 1 12 Shows the previous measurement This button is enabled only when a previous measurement is present 6 2 1 13 SHOW NEXT MEASUREMENT Shows the next measurement This button is enabled only when a next measurement is present 6 2 1 14 DISPLAY GRAPH OPTI ONS C This button opens up a new window Figure 6 2 1 Graph Control allowing you to control the graph properties Please refer MAL Inc User Manual for CutPro exe 197 to
77. Single time domain simulation for one cutting condition in chatter free area Spindle speed 14300 rpm 6 mm depth of cut 8 1 4 Ex04_ MultipleAnalytical csf Multiple Analytical Simulation for Regular pitch cutter This is a Stability lobe simulation for cylindrical end mill in 3 dimensions which are depth of cut spindle speed and width of cut 8 1 5 Ex05_Optimumpitch_5000 csf Optimum variable pitch cutter design simulation at 5000 rpm for 4 flutes cutter Optimize the tool flute angles to obtain as much as possible high chatter free depth of cut 8 1 6 Ex06_SingleAnalytical_ Var csf Single Analytical Simulation for Variable pitch cutter This is a Stability lobe simulation for cylindrical end mill 8 1 7 Ex07_CuttingCoef csf This calculates the average cutting coefficients from milling experimental cutting forces Experimental cutting conditions for the files Cutting type Slotting depth of cut 2 0 mm Workpiece material Al 7075 Cutter 4 flutes 30 degree helix angle 8 1 8 Ex08_SingleTime_BallEnd csf Single time domain simulation for Ball End Mill cutter MAL Inc User Manual for CutPro exe 236 8 1 9 Ex09_SingleTime_GeneralEnd csf Single time domain simulation for General Solid End Mill cutter 8 1 10 Ex10_SingleTime_InsertCutter csf Single time domain simulation for an inserted cutter 8 1 11 Ex11_SingleTime_Static_InsertCutter csf Single time domain simulation for an inserted cutter without vibration 8 1
78. SingleTime_InsertCutter csf cccceeeeeeeeeeeees 236 8 1 11 Ex11_SingleTime_Static_InsertCutter csf 008 236 8 1 12 Ex12_SingleAnalytical MAWD cCSFf cceeeeeeeeeeeeeeeeees 236 8 1 13 Ex13_Temperature_Milling Csf ccccceeeeeeteeeeeeeeenees 236 8 2 EXAMPLE A SIMULATING A DESIRED MILLING PROCESS wameencseneee eee temsen cee cee wees mess seebweweurenseeewceweeeneesnseeeweeres 236 8 2 1 OBTAINING THE STABILITY LOBES cccccceeeeee ees 237 8 2 2 SIMULATING THE MILLING PROCESS AT 6000 RPM 239 8 2 3 SIMULATING THE MILLING PROCESS AT 14300 RPM 241 8 2 4 OPTIMIZING VARIABLE PITCH ccccccceseeeeeeeeeeeeees 242 8 2 5 CHECKING THE STABILITY LOBES FOR THE OBTAINED VARIABLE PITCH aesir E E EE E 244 8 3 EXAMPLE B OBTAI NI NG STABILITY LOBES IN A MULTI PLE STEPS PROCESS sussssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 246 8 4 EXAMPLE C OBTAI NI NG CUTTI NG COEFFI CI ENTS IN MILLING wccteccutewsnaieesenuwe siete vacewecaveuscevewvectcecasuvewsseuscetanuserewsvere 248 8 5 EXAMPLE D OBTAINING MAXIMUM TEMPERATURE ALONG CUTTER ROTATION cccscccccccccsnnnnneeeeececennnnneeeeeeeens 250 9 APPENDIX A vcscisnseieneieveensansiwsnenitersstenrereeeiaverees 253 9 1 Appendix Al UNITS ssisieisiciticcssnetecccnsesssiencinnrtenenens 253 9 2 Appendix A2 Modal Residue data files ssssssssnsnn 253 9 3 Appendix A3 Dynamic ParameterS ssssssss 2 254 9 4 Appendix A4 How CutPro Calculates Dynamic Ch
79. TYPE TAB 67 MAL Inc User Manual for CutPro exe 3 1 4 MACHINE amp TOOL CUTTER PROPERTIES TAB 0085 7 3 1 5 MACHINE amp TOOL STRUCTURAL FLEXIBILITY TAB 89 3 1 6 WORKPIECE MATERIAL TAB isinccicccivncuabasmaceneenenenngsantas 95 3 1 7 WORKPIECE STRUCTURAL FLEXIBILITY TAB 114 3 1 8 CUTTING CONDITIONS MILLING MODE TAB 114 3 1 9 CUTTING CONDITIONS OTHER PARAMETERS TAB 122 3 1 10 TEMPERATURE PROPERTIES TAB ccc cece eee 127 3 2 PLUNGE MILLING MODULE sssassnssnsnnnnnnnsnnnnnnnnnnnnnnn 129 3 2 1 GENERAL SIMULATION MODE TAB ccccceccee cess seen ee ees 129 3 2 2 GENERAL OUTPUT WA Bicctccioerduomtnoneendustaentansonaecemanmens 130 3 2 3 MACHINE amp TOOL TOOL TYPE TAB ccc cecceeeeee ee ee eens 131 3 2 4 MACHINE amp TOOL TOOL PROPERTIES TAB 065 134 3 2 5 MACHINE amp TOOL STRUCTURE FLEXIBILITY TAB 135 vO WORKPIECE TAD eeen a a 136 3 2 7 CUTTING CONDITIONS TAB 1 cece eee eee steers 136 3 3 TURNING MODULE ccccccccccccceceeeeeneeeeeeeeeeeeeeeneneees 139 3 3 1 GENERAL SIMULATION MODE TAB ccccccceee cesses ee eens 139 3 3 2 GENERAL OUTPUT TAB isssccsincsecccaesanvssoreantecieanteseanaes 140 3 3 3 MACHINE amp TOOL CUTTER PROPERTIES TAB 4 141 3 3 4 MACHINE amp TOOL STRUCTURAL FLEXIBILITY TAB 142 3 3 5 WORKPIECE MATERIAL TAB ccc cece eee e ener eee e eee eeeees 143 3 3 6 WORKPIECE STRUCTURAL FLEXIBILITY TA
80. Ter Ioj x Maximum Temperature History Along the Cutter Rotation Taag o Maximum Temperature A Max Allowable Temperature iT m m Li Ta E a CL bei cL H Cutter Rotation E a e uv s 51 130193 Miptians Coord s Zoom Reset 2171 Dany Figure 9 8 5 1 Maximum Temperature History result from Example D Note that the temperature along the cutter rotation is below the maximum allowable temperature of 1100 C MAL Inc User Manual for CutPro exe 253 9 APPENDIX A 9 1LAppendix A1 Units Metric Units Imperial Units Newton millimeter squared Pound force squared inch N mm Ibf in7 Newton meter N m Pound force foot Ibf ft Meter Newton m N Foot pound force ft Ibf Newton meter N m Pound force foot Ibf ft Gram centimeter cube Pound inch cube Ib in gt g cm Newton meter squared N m Pound force squared inch Ibf in7 Degree Celsius C Degree Fahrenheit F Imperial hp Watt meter Kelvin W m k Foot pound inch hour in hr ft2 F 9 2Appendix A2 Modal Residue data files X Uses a file containing modal parameters modal residue These modal parameter files are created file using the modal analysis program Y Uses a file containing modal parameters modal residue These modal parameter files are created file using the modal analysis program Modal analysis program creates an ASCII file as follows Example MODES
81. Type tab in Plunge Milling module Tool Type Tool Properties This tab allows you to choose the cutter type to define number of flutes and run out deviations 3 2 3 1 TOOL TYPE There are two options for the tool type Symmetrical tool and Unsymmetrical tool When you choose the tool type a figure will show general look of the selected tool on the right hand side of the Simulation Properties The figure will also help you visualize the parameters on the tool when you change them on the Tool Properties tab MAL Inc User Manual for CutPro exe 132 Plunge Mill Geometry Figure 3 2 4 Symmetrical tool in Plunge Milling module Plunge Mill Geometry Figure 3 2 5 Unsymmetrical tool in Plunge Milling module F MAL Inc User Manual for CutPro exe 133 3 2 3 2 RUN OUT DEVIATIONS OF FLUTES You can define the radial and axial run out deviations of each flute Click the View button to open the Run out Window and in the Run out window double click the cell in the grid of which you want to edit the value You can edit the run out deviation in the opened edit window Run Out Radial Runout Input nout value Cancel Figure 3 2 6 Run out edit windows in Plunge Milling module MAL Inc User Manual for CutPro exe 134 3 2 4 MACHINE amp TOOL TOOL PROPERTIES TAB Plunge Milling Simulation Properties Machine amp Tool lt gt fl X vo Tool ropenes Back Mex Tabs Cancel OK General Work p
82. ake face and the clearance edge Applies to milling only If maximum temperature history along the full cutter rotation below is selected this defines in how many increments the temperature Simulation calculates the cutter temperature along the cutter rotation The temperature simulation converges the temperature along the rake face with the matching temperature along the contact length of the chip This defines the maximum allowed difference between these two temperatures Applies to turning only This defines the width of a groove if any in the workpiece Applies to turning only This defines the diameter of the rotating workpiece Applies to milling only If checked temperature is calculated at a series of increments along the cutter rotation see above Applies to milling only If checked temperature distribution is calculated for the chip and cutter and the exit angle only Applies to milling only If checked results for tool and chip temperature distribution are enabled You must have MatLab installed in order to view these MAL Inc User Manual for CutPro exe 129 results 3 2 PLUNGE MILLING MODULE S251 GENERAL SIMULATION MODE TAB Plunge Milling Simulation Properties Genera gt fe e y simulation Mode Next Tabs Cancel Ok General Machine amp Tool Workpiece Cutting Conditions Static Analysis Simulates cutting forces spindle power and torque when tool and workpiece can be assu
83. al shearing coefficient 1 N mm Ktc2 Tangential shearing coefficient 2 N mm Krc2 Radial shearing coefficient 2 N mm Kac2 Axial shearing coefficient 2 N mm t Boundary chip thickness at which parameters 1 change to parameters 2 mm EXPONENTIAL CHIP THICKNESS The cutting coefficients are exponentially related to chip thickness In the following figure you can see Exponential chip thickness model frame in Material Editor window Exponential chip thickness model Edit Equation Figure 3 1 84 Exponential chip thickness model frame in Material Editor window The following parameters are used in order to define exponential chip thickness model Table 3 1 245 Parameters for Exponential chip thickness model KT Tangential shearing coefficient parameter MAL Inc User Manual for CutPro exe 111 KR Radial shearing coefficient parameter KA Axial shearing coefficient parameter p Tangential chip thickness order q Radial chip thickness order r Axial chip thickness order SEMI MECHANISTIC The cutting coefficients are functions of two main coefficients and the geometry of the tool Serm mecharizthe madel Edit Equation Figure 3 1 85 Semi mechanistic model frame in Material Editor window The following parameters are used in order to define the semi mechanistic model Table 3 1 256 Parameters for Semi mechanistic model Kn cutting pressure on rake face N mm kf cutting pressure rate
84. ameters Cutting conditions tab Cutting properties Maternal editor Cutting tool tab Cylindrical eridmil gt Print Cancel Figure 1 3 13 Help menu in CutPro Contents and Index window Index option MAL Inc User Manual for CutPro exe 28 H CutPro Untitled csf File Simulation Results Tools Window Help Help Topics CutPro 6 0 x Contents Index Find 1 Type the word s you want to find about l SLI i 3 Click a topic then click Display Activating Modules Average cutting coefficient model Equations Average cutting coefficient model M aterial editor Ball end erndmill Bi lin ar force model Equations Bilinear force model Material editor A 112 Topics Found All words Begin Auto Pause J Print Cancel Figure 1 3 14 Help menu in CutPro Contents and Index window Find option ut CutPro Untitled csf File Simulation Results Tools Window Help i License Information Serial A400 Please check each module below for which you have a valid password Enter the password for each then click Yerity New Machining Process Turning Simulation Boring Simulation Drilling Simulation Temperature Simulation Modal Analysis M MalTF MalDAg SpindlePra Simplified Milling Simulation Virtual CHC TTA Verify Done hi l Figure 1 3 15 Help menu in CutPro License information window MAL Inc User Manual f
85. ameters of the insert Edit Insert Cutter Types Insert type Rhombic HY New Comer Angle deg A Edge Length mra 10 I Scale 144 oom In oor Out Cancel Figure 3 2 9 Edit Insert type for Plunge Milling Module EEAS MACHINE amp TOOL STRUCTURE FLEXIBILITY TAB The Machine amp Tool Structural Flexibility tab allows you to enter machine amp tool dynamic parameters You can model the machine amp tool as Rigid or Dynamic vibrations For dynamic machine amp tool you need to know the MAL Inc User Manual for CutPro exe 136 dynamic parameters of the machine amp tool You can enter the natural frequencies damping ratios and stiffness for up to 6 directions X Y Z O ZO OZ Dynamic parameters Direction me tf Z w KEG Hr Mode no Mat freq Hz 416 07 514 56 321 5000 5000 5000 Damping ratio 0 04390 0 05098 0 04822 0 00243 0 00753 0 00230 Stiffness N m 1 34E 40 4 436 40 2 426 40 111 E40 2 126 40 7 36E 0 Rigid E E E E i aj SS a art Next gt Figure 3 2 10 Machine amp Tool Dynamic Parameters amp If you select the Static Analysis simulation mode the machine amp tool are considered as rigid 3 2 6 WORKPIECE TAB This tab allows to select or define the material of the workpiece For defining a workpiece material refer to 3 1 6 1 Define a Workpiece Material in 2 2 Axial Milling The workpiece is considered as rigid for all simulation modes in p
86. ample files provided 6 4 FRF FILES FORMAT Unless specified as HP SDF format see below FRF files must be ASCII text files consisting of three columns containing the following parameters The widths of the columns in characters are 14 15 and 15 MAL Inc User Manual for CutPro exe First Column Frequency Hz For example 6 5 DEFINING AND OPTIMIZING MODES IDENTIFYING A MODE 6 5 1 B TestFRFX11 frf Notepad iols File Edt Search Help Second Column Third Column Real HHH 250000 S 66888 58086 888088 250000 5006H S0HG G 886088 250000 0000H 58886 866088 2560808 SBAR88 part of transfer function 341797 292969 2414 195313 195313 146484 146484 195313 146484 097656 048828 146484 146484 195313 195313 Imaginary part of transfer function 0A0HAGA 89 7656 146484 146484 89 7656 89 7656 048828 097 5 146484 89 7656 048828 0AOHAGH HHAGAG 048828 048828 Figure 6 4 1 A sample FRF file 202 Use the left and right mouse buttons to define the left and right boundaries of a mode respectively a mode is represented by a peak in the plot A vertical green line marks the beginning of the mode and a vertical red line marks the end of the mode Figure 6 5 1 MAL Inc User Manual for CutPro exe See 203 M 3D Modal Analysis ExX_FRF mod ioj x File Modes Results Options Tools elal Hlo
87. and torque when tool and Static Analysis sui workpiece can be assumed to be rigid Simulates cutting forces tool vibrations spindle power and torque C Dynamic simulation nul Ina time domain r Analytical stability A fast analytical stability lobes prediction solved in a frequency lobes domain Figure 2 1 18 The Static Analysis simulation mode is selected in the General tab of the Plunge Milling module MAL Inc User Manual for CutPro exe 44 In this simulation mode the cutting forces in x y and z directions the resultant cutting force in xy plane and the spindle torque and power are simulated based on the cutter geometry and the machining parameters This mode assumes both the workpiece and the tool are rigid 2 1 2 2 DYNAMIC ANALYSIS H CutPro Untitled csf Fie Simulation Results Tools Window Help Dy pi E D H k mg i f EEF New Open Save Properties Run Run Temp Modal Ma Machining Process Gererzi gt x z i i Hide simulation Mode Next Tabs Cancel OK eo General Machine amp Tool workpiece Cutting Conditions Static Analysis Simulates cutting forces spindle power and torque when tool and workpiece can be assumed to be rigid Simulates cutting forces tool vibrations spindle power and torque f Dynamic simulation In a time domain a Analytical stability A fast analytical stability lobes prediction solved in a frequency lobes domain Figure 2 1 19 The dynamic para
88. angential edge force coefficient N mm radial edge force coefficient N mm axial edge force coefficient N mm tangential shearing coefficient N mm2 radial shearing coefficient N mm axial shearing coefficient N mm 2 MAL Inc User Manual for CutPro exe 263 10 2 Appendix B2 Bi linear force model Equations dF K dS K h dz dF K dS K h dz dF K dS K h dz Ke 0 0 i Ke K a K 0 0 K K tifh lt t 0 0 K K K K tl K t gt Ke Ko te K K K t K K bif h gt t re Ke K acl Kyo f gt K K Force PN l l l fel l l l N PN Kac rez gt ac2 i chip thickness h Ft differential tangential force N Fr differential radial force N MAL Inc User Manual for CutPro exe dFa ds dZ Kte Kre Kae Ktc Kre differential axial force N differential cutting edge length mm differential axial depth of cut mm chip thickness mm tangential edge force coefficient N mm radial edge force coefficient N mm axial edge force coefficient N mm tangential shearing coefficient N mm 2 radial shearing coefficient N mm2 axial shearing coefficient N mm2 MAL Inc User Manual for CutPro exe 264 10 3 Appendix B3 Exponential thickness Equations dF K dS K h dz dF K dS K h dz dF K dS K h dz K K K 0 0 K KT h K KR KT h K KA KT h dFt differential
89. ank Diameter D2 rrn Fn Tool Overhang Length L rim 0o Cutter Diameter D1 rn ie Cutter Length Lifmm 35 Tool Material Carbide Figure 6 9 6 Tool Coupling dentification Geometry Parameters Although it is recommended to use a blank tool to perform the experiments in the case an end mill is used to perform the experiments the software allows the user to input the end mill geometry Tool Dimensions Measurement Point nim fo Tool Shank Diameter Dimm 2 T l Tool Overhang Length Le mm 50 Cutter Diameter Dimm PE Cutter Length L1 mm 35 Tool Material Carbide Figure 6 9 7 Tool Coupling dentification Geometry Parameters The cutter diameter for a 4 fluted end mill is 80 of the tool shank diameter Press Next to input the FRF impact measurements 6 9 4 3 2 IDENTIFICATION IMPACT MEASUREMENTS MAL Inc User Manual for CutPro exe 217 Import the 3 measured FRF files in Figure 7 9 2 Figure 7 9 3 and Figure 7 9 4 respectively The measured frequency response files have to be displacement force FRF s C ReceptanceCoupling AE Options Help lt gt xX ToolHolder Spindle Open Save Back Next Exit mpact Measurements EEE identification Geometry Parameters E impact Measurements ES 7 ool Coupling Import TF Running Identification Figure 6 9 8 Tool Coupling Identification I mpact Measurements Press the Running I
90. are required Direct Transfer Function Measurement at the tip of the holder shank TF 11 Figure 6 9 18 Tool Tool Holder assembly to spindle direct transfer function measurement at the tip of the holder shank TF 11 Cross Transfer Function Measurement between the tip of the holder Shank and the tool holder flange TF 12 Figure 6 9 19 Tool Tool Holder assembly to spindle cross transfer function measurement between the tip of the holder shank and the tool holder flange TF 12 Direct Transfer Function Measurement on the tool holder flange TF 22 Figure 6 9 20 Tool Tool Holder assembly to spindle direct transfer function measurement on the tool holder shank TF 11 MAL Inc User Manual for CutPro exe 223 6 9 5 2 IDENTIFICATION USING THE SOFTWARE To start select Identify Spindle Holder Connection button Coupling of Holder and Tool Assembly to gt pindle Identify Spindle Holder Connection C Load Existing SpindlefHolder Connection Figure 6 9 21 Tool Tool Holder assembly to spindle Identification 6 9 5 2 1 IDENTIFICATION GEOMETRY PARAMETERS Input the shrink fit dimensions used to perform the experiments The dimensions are provided in the tool holder manufacturer catalogue C ReceptanceCoupling Seles File Options Help l A lt gt x Spindle i ao Open Save Gack Next Exit r Select Shrink Fit Toolholder to Perform Experiments Tool Holder Geometry
91. at PF fon Back rake angle ep PF o Relief angle ei 1E z Tool Nose Radius R mm U8 This parameter is ignored for Mechanistic Model This parameter is only used in Temperature module Tool Properties Structural Flexibility Figure 3 3 3 Machine amp Tool Cutter Properties tab of the Turning Module This tab allows you to specify the cutter material This tab is exactly the same as the Cutter Properties tab in the Advanced Milling Module in Section 3 1 4 MACHINE amp TOOL CUTTER PROPERTIES TAB MAL Inc User Manual for CutPro exe 3 3 4 142 MACHINE amp TOOL STRUCTURAL FLEXIBILITY TAB Machine amp lool lt gt Le E ow Back Mext Tabs Cancel DK Workpiece Cutting Conditions Temperature Structural Flex iouity Machine amp Tool General Machine amp Tool Model Feed f Rigid Dynamic vibrations Dunamnic parameters Direction Aadial Tangential Mode no 1 1 Nat freq Hz 5o fo fo amping ratio pbo oO fo Stiffness Mam T0007 fo fo p z M Delete Insert Static deflections Machine Dynamics Hode ext gt i Measured EF file Rigid Modal residue data files 4 Previous f Dynamic parameters Structural Flexibility Tool Properties Figure 3 3 4 Machine amp Tool Structural Flexibility tab This tab allows you to edit the structural flexibility of the machine Note that this vers
92. ation Properties changes automatically when any of the tool parameters is changed On the Machine amp Tool Cutter Properties tab you can also define a profile for serrated cutters Figure 3 1 46 Serrated Cutter When you click the Serrated Cutter check box the Spline File window shows up Figure 3 1 47 The Spline File window You can also open the The Spline File window window by clicking on the File button in Figure 3 1 46 Table 3 1 8 Functions of the buttons on Spline File window Open Open an existing Spline csp file Edit Edit the currently selected Spline file This brings up the Spline Editor window Create Create a new Spline file This brings up the Spline New Value Editor window OK Select the current file and close the window Cancel Close the Spline File window and revert to the previously selected file When you click OK in the The Spline File window window the Spline Value Editor window pops up in which you define coordinates of the point on the serration profile MAL Inc User Manual for CutPro exe 81 w Spline Yalue Editor Ioj x File Edit Units Help Slope of curve at the Start Point BC jo Slope of curve at the End Point BC2 jo Y mrm Iw ave Length iw ave Amplitude Figure 3 1 48 The Spline Value Editor window The Spline Value Editor window consists of a table In Figure 3 1 48 the first column lists x coordinates of the points while the second o
93. ave a non uniform pitch cutter your feed rate will be calculated as follows MAL Inc User Manual for CutPro exe 116 f flute pitchangl feedrate mm tooth entereeedratelmmtoorh numberof inte pitchanglel deere Enter the Spindle Speed in RPM Available only for certain simulations a Enter the Axial Depth of Cut Axial Depth of cut Enter the number of revolutions Available only for certain simulations Enter the sampling frequency scale Available only for certain simulations Enter the Material Surface Removal rate and Surface Speed Available only for certain simulations e Enter the value of radial width of cut based on the following milling mode description starting from Section 3 1 8 3 1 8 1 1 DOWN MI LLI NG Radial width of Distance from the top of the workpiece to the cut lower edge of the cutter Must be a positive value MAL Inc User Manual for CutPro exe 117 Simulation Properties Milling Mode Back Next Tabs Cancel OK Genel Machine Tool workpiece Cutting Conditions Temperature Feedkate mmvthte 0 05 Spinde speed RPM 4553 333 Axial depth of cutfalimm 5 Humber of ravoluiorns mr ea Figure 3 1 91 The Cutting Conditions Milling Mode tab Down milling is selected in this figure 3 1 8 1 2 UP MILLI NG Radial width of Distance from the bottom of the workpiece cut to the upper edge of the cutter Must be a positive va
94. be made on this tab Click Next to go to the Machine amp Tool Cutter Type tab Select Cylindrical endmill and 4 flutes for this example MAL Inc User Manual for CutPro exe 243 Click Next to go to the Machine amp Tool Cutter Properties tab Select Carbide for the cutter material from the drop down menu Enter the same parameters as in the previous sections in this example Click Next to go to the Machine amp Tool Structural Flexibility tab Select Dynamic vibrations for the machine amp tool model and enter the same dynamic parameters as before 500Hz for X 7OOHz for Y Click Next to go to the Workpiece Material tab Select Aluminum AL356 T6 for the material of the workpiece Select Average cutting coefficient mode for the purpose of this example Click Next to go to the Workpiece Structural Flexibility tab The workpiece is assumed to be rigid in this example Select Rigid Click Next to go to the Cutting Conditions Milling Mode tab Select Clockwise spindle direction and downmilling Enter the desired feed rate 0 05mm flute and the desired spindle speed 5000RPM The surface speed is dependent on the two parameters mentioned Enter the radial width of cut as mentioned before 9 525mm Click Next to go to the Cutting Conditions Other Parameters tab Three pitch distribution types can be selected For the purpose of this example the type Two different angles is selected Enter 0 as the starting angle The increme
95. bility lobes in time domain and single analytical stability lobes The sample results window of the milling process simulation mode is shown in the following figure MAL Inc User Manual for CutPro exe Forces W i li l sil aA M ul Force N il Sij m is i il i HiT FA TY Deflection daha Figure 2 1 5 Sample Results window of Single Time Domain mode Time sec F MAL Inc User Manual for CutPro exe 35 2 1 1 2 STABILITY LOBES IN TIME DOMAIN W CutPro Untitled csf File Simulation Results Tools Window Help Mew Open Save Properties Run Run Temp Modal y i D H of Machining EESE A perties Process Genera gt fried yY simulation Mode Merck Tabs Cancel Ok General Machine amp Tool workpiece Cutting Conditions Temperature Single analytical 4 fast analytical stabilty lobes prediction solved in a frequency stability lobes domain Milling process Simulates cutting forces tool vibrations surface finish spindle simulation power and spindle bending moment in a single tine domain Multiple analytical Generates stability lobes with axial and radial depths of cut and stability lobes spindle speed Stability lobes in time Use this mode to simulate stability lobes within a narrow speed range domain fora complicated cutter Otherwise see below Optimize variable Automatically calculates pitch distibution at a specific spindle pitch speed for a given number
96. can see the brief definition of these parameters in the following Starting This is the spindle speed you wish to start your Speed time domain simulation End Speed This ts the spindle speed you wish to end your MAL Inc User Manual for CutPro exe 123 time domain simulation Speed This is the spindle speed increment at which the Increment simulation is executed amp Note that depending on the selected speed range and speed increment the simulation time may vary 3 1 9 1 3 SINGLE ANALYTICAL STABILITY LOBES For this simulation mode there is no other parameter to be defined 3 1 9 1 4 MULTIPLE ANALYTICAL STABILITY LOBES w CutPro BoeingTool_7 csf File Simulation Results Tools Window Help 1 m Mew Open Save Properties Run d Run Temp d T Plat All lin Mal Q SpindleFro Animation Modal Machining ETNEA a E Process cutting Conditions lt gt i tel y Diner Parameters Back Next Tabs Cancel Ok General Machine amp Tool workpiece Multiple Analytical Stability Lobes Y start offset y mm 19 05 end offset Yan mm 19 05 Start width hy mm 9 525 End width h mm 3 525 Workprece width vw mm 35 1 Step mm 19 05 z r a g LL Boring B Drilling Number of analytical simulations Hilling to perform 3 Advanced Figure Multiple analytical stability lobes Prediction of _ ____ cutting Miling Mode Other Pa
97. ce E E 191 MAL Inc User Manual for CutPro exe 5 3 14 EXPERIMENTAL AVERAGE CUTTING FORCEG 192 MODAL ANALYSIS sascecsspsscecesnassnnss coxespeseaesesaneeawes 193 6 1 3D MODAL ANALYSIS MENU sssssssnsnnsnnsnnnnsnnnnnnnnnnnn 193 6 2 MODAL ANALYSIS WINDOW TOOLBAR BUTTONS 195 Oza TOP TOOLBAR sarare niriana T E enonseeaminn com 195 6a BOTKOM TOOLBAR crecieron aaa 198 6 3 SELECTING FRF FILES ccccssssseeeeeeeeeeeeceeeeceeenaaaas 199 0 50 BROWSING THE FILES saiac cre nsnacueneceatiawaneeanes sauna sas 199 Oa MODAL MODEL onar aA nase cersownascwanes 200 Oo PR TPE e A E E EEE E E 200 oaa IMPACT POINT mirena E E 200 65 2 GAINCONS TANT aiestersncswersscanseruetes toes vatoutsenwateussns 200 Oro PREOUENCYT RAINGE airiran nrn E 201 Sone DUTTON rrr A E scent 201 6 4 FRF FILES FORMAT cccccccccccccccecneneeeeeeeeeeeeeeennenees 201 6 5 DEFINING AND OPTIMIZING MODEG ccccccseeees 202 6 5 4 JIDENTIPVING A MODE paaien vasmneeriaasereneense 202 6 2 ADDING THE MODE lt sscceeecenscesactascetnssereteecamneeenenesens 204 Oa DELETING A MODE sarrere rE E 204 0 9 4 PECOFTING ALL THE MODED srrnsasreirinni ienen 204 0 5 9 OPTIMIZING THE MODES rsrirerersinnia ra une ANTRENE 205 6 5 6 VIEWING THE SHAPE OF A MODE ccccc cece cece eee ees 206 6 6 SAVING MODAL PARAMETERS ccccccccccceeeeennnnnaaes 206 6 7 USING MODAL PARAMETERS IN CUTPRO 208 6 8 TRANSFER FUNCTION MEASUREMENT FRF FILES 209 6
98. d coupling of Shrink fit tooling to the spindle 3 Tool Length Tuning Guides in the selection of the optimum tool length for the selected tooling It optimizes the tool length to achieve maximum productivity by utilizing the maximum spindle speed on the machine F MAL Inc User Manual for CutPro exe PAW C ReceptanceCoupling Fie Options Help Tool Coupling C Identity ToolHolderfSpindle Assembly Load Existing ToolHolderfSpindle Coupling of Holder and Tool Assembly to opindle C Identity SpindlefHolder Connection Load Existing spindlefHolder Connection L Ta d k C Tool Length Tuning Figure 6 9 1 Receptance Coupling Functions 6 9 4 TOOL COUPLING 6 9 4 1 APPARATUS It is recommended to use a medium length blank tool to perform the experiments to identify the tool holder spindle assembly 1 Short blank tool 40 mm 2 Long blank tool 120 mm or higher MAL Inc User Manual for CutPro exe 213 d I aHa Taa Blank Lang plank MAL Inc User Manual for CutPro exe 214 6 9 4 2 EXPERI MENTAL ANALYSIS amp Note Consistent frequency range and freq interval are needed for the experiment Insert the blank tool into the holder so that the stick out L2 is 40 50 mm The length inserted inside of the tool holder does not play an important role although it has to be in the range recommended by the tool holder manufacturer Attach an accelerometer on the blank tool and apply the impact ham
99. de no Nat freg Hz So F nos Joo Damping ratio fpo SHiffness N m f 1 00E 07 1 00E 07 a Rigid E lt Previous Delete Insert ext gt Figure 3 1 68 The Dynamic Parameters frame on the Machine amp Tool Structural Flexibility tab Table 3 1 155 Buttons in the Dynamic Parameters frame Previous Switch to previous modes to view and edit the dynamic parameters of the modes Delete Delete the current mode with its dynamic parameters Insert Add a new mode with its dynamic parameters Next Switch to next modes to view and edit the dynamic parameters of the modes For any of the above modes you have an option to make any direction of the structure rigid by clicking the related check box below the parameter text boxes Please see Section 10 3 Appendix A3 Dynamic Parameters for more information amp If you select the Static deflections option for the machine amp tool model the workpiece model options are disabled amp If you select the Rigid option for the machine amp tool model and the workpiece model the only simulation modes available are Single time domain and Cutting coefficient identification amp If you select the Dynamic vibrations option for the machine amp tool model go to the Dynamics tab to specify parameters or source data files En MAL Inc User Manual for CutPro exe 95 3 1 6 WORKPIECE MATERIAL TAB W CutPro Untitled csf Fie Simulation Results Tools Window Help D H N
100. dentification Button to start the Identification procedure Running Identification Figure 6 9 9 Tool Coupling Running Identification It will open a command window and will take a few minutes depending on the frequency selection and the speed of the computer Z Figure 6 9 10 Running Receptance Coupling Engine Once the identification procedure is complete a prompt save window appears Press Save The software saves the identified spindle tool holder assembly project file with the measurement files F MAL Inc User Manual for CutPro exe Ci Rece ptanceCoupling File Options Help ToolHolder Spindle Save EE identification Save in E ReceptanceCoupling ur cE Ez Geometry Parameti peojtect Impact Measure Me ool Coupling 2 hy Documents bly Network File name Untitled re Places Save as type Receptance Coupling Files rcf Figure 6 9 11 Tool Coupling Save Project File Press Next to Tool Coupling 6 9 4 4 TOOL COUPLING BE ReceptanceCoupling Wee Options Help Co A ToolHolder Spindle lt gt Open gave Back Mext Tool Dimensions Exit BS dentification Geometry Parameters Impact Measurements EEE Tool Coupling Tool Material Carbide Tool Coupling Export Resulting FAF Plot in MODAL Figure 6 9 12 Tool Coupling Assembly Ery MAL Inc User Manual for CutPro exe Tool Dimensions Cancel Measurement
101. dial width of cut The sample result window of the single analytical stability lobes mode is displayed below MAL Inc User Manual for CutPro exe 38 x Stability Lobes Analytical o E 7 5 E A ha i a IE TMI ACY a i Soo indon isdo0 20000 25000 aodio Spindle Speed rpm Figure 2 1 9 The sample Result window of the Single Analytical Stability Lobes mode 2 1 1 4 MULTIPLE ANALYTICAL STABILITY LOBES Fie Simulation Results Tools Window Help D H k Wo ae E ia Pew Open Save Properties Run Run Temp Flot All Simulation Properties Gererat gt gt Hiel 4 SUunufation MOJE Back Merck Tabs Cancel OK Machining Process General Machine amp Tool Work piece Cutting Conditions Temperature Simulates cutting forces tool vibrations surface finish spindle Single time domain power and spindle bending moment in a single time domain r Stability lobes in time Use this mode to simulate stability lobes within a narrow speed range domain for a complicated cutter Othenvise see below c Single analytical A fast analytical stability lobes prediction solved in a frequency stability lobes domain iz Multiple analytical Generates stability lobes with axial and radial depths of cut and cstability lobes spindle speed cr Optimize variable Automatically calculates pitch distribution at a specific spindle pitch speed for a given number
102. dius of the tool and width of cut respectively 3 1 8 3 GENERAL ENDMILL Parameters are the same as in Ball Endmill 3 1 8 4 I NDEXABLE CUTTER Parameters are the same as in Ball Endmill MAL Inc User Manual for CutPro exe 122 3 1 9 CUTTING CONDITIONS OTHER PARAMETERS TAB The cutting conditions parameters in this section vary depending on the simulation mode selected under the General Tab Refer to the pages on a specific simulation mode for details 3 1 9 1 SIMULATION MODES 3 1 9 1 1 SINGLE TIME DOMAIN For this simulation mode there is no other parameter to be defined 3 1 9 1 2 STABILITY LOBES IN TIME DOMAIN 4 CutPro Untitled csf File Simulation Results Tools Window Help Oo ow tA Mew Open Save Properties Run Lb Run Temp Plot All lin lt p Modal Mal F Malb Q SpindlePro Animation Machining RIDE at ttn gat Process Cutting Conditions gt hel E Ofer Parameters Bak Next Tabs Cancel OK E N F General Machine amp Tool workpiece Hilling Spindle Speed Range APM Starting speed 2000 End speed 1 00E 04 Speed increment 100 Hilling Advanced Prediction of cutting Milling Mode Other Parameters on oe Figure 3 1 96 Cutting Conditions Other Parameters tab in Stability Lobes in Single Time Domain simulation mode For this simulation mode you will define Spindle Speed Range for the time domain simulation on this tab You
103. dle Torque MAL Inc User Manual for CutPro exe 174 5 4 2 8 TEMPERATURE HISTORY Temperature History Untithed cst i o x Temperature History Aamin Tempe rat r z Wan l Tempe rati re so DETJE Tempe rat re ha Q m E co _ T i D H 0 0 000 0 002 0 004 0 006 0 00g Time s w aD o Eg pws xi 0 013563 Options Coord s Zoom Reset Y 169411484 This plot shows the temperature history during the cut Please refer to Section 3 1 10 TEMPERATURE PROPERTIES for more information regarding Temperature Simulation MAL Inc User Manual for CutPro exe 175 5 4 2 9 RAKE FACE TEMPERATURE FROM TOOL TIP T ao 2 i w OS i 3 5 O Distance from Tool Tip mm 2 wih EOS jms xi 5 400426 Options Coord s Zoom Reset Y 5 3879E 09 This plot shows the temperature profile along the rake face of the tool measured from the tool tip to the contact length MAL Inc User Manual for CutPro exe 176 5 4 2 10 PERCENTAGE OF HEAT ENTERING THE TOOL Percentage of Heat Entering the Tool Untitled csf O x Percentage of Heat Entering the Tool ps Fore EOS ps 0 31981 Ciptions Coord s ogm Reset t 06 807491 This plot shows the percentage of heat entering the tool as a function of the fractional length along the contact length on the tool rake face I Icn Please refer to Figure 5 4 2 1 below to get a definition for and Icn MAL I
104. e sec te wi BOs we m 0 188094 Options FFT Coord s Zoom f Larae Reset Figure 3 1 13 Spindle torque Spindle Bending Moment Untitled cst Spindle Bending Moment Instantaneous E e Cumulative I Average Z WA a D fy 0 00 0 05 0 10 Time sec So o te ea EOS js Options FFT Coord s Zoom a 0 249617 Reset Y 2r 942609 Figure 3 1 14 Spindle bending moment at the first spindle bearing location MAL Inc User Manual for CutPro exe 63 The General Output tab also allows you to save data for a milling animation You must check the Save milling animation data check box in order to enable this option simulation Properties General lt gt fel y Output Back Next Tabs Cancel OK General Machine amp Tool Work piece Cutting Conditions Temperature Check the output data you want to be saved as text files during the simulation iw Cutting forces weal nell Ciba Animation Options iw Workpiece vibrations Starting revolution U i Surtace finish Sie EME Te W Spindle power amp torque Starting level D Spindle bending moment End level D We Chip thickness After you have ruin the simulation pou map Welw the milling animation by clicking the Animation button on the main toolbar Simulation Mode Output Figure 3 1 15 Save data for milling animation You have to enter the parameters in the Animation Options frame which are d
105. e workpiece is also assumed to be rigid in Cutting Coefficients Identification Click Next to go to the Cutting Conditions Milling Mode tab The spindle direction can only be clockwise and the milling mode can only be slotting in this simulation mode Enter the axial depth of cut which is 2mm for this example Click Next to go to the Cutting Conditions Other Parameters tab Select Average Method as the cutting coefficient calculation method Click Browse for the experimental cutting forces for a particular feed rate and enter the feed rate as well Click Next to enter the next set of data and its corresponding feed rate The Experimental Cutting Forces files for this example are under the names ExpCutForce_050_2 txt ExpCutForce_0O 75_2 txt etc Click Next to go to the Temperature Properties tab We are not interested in the temperature simulation for this process Click Run to run the simulation Click Results gt Plot gt Exp Average Cutting Forces to plot the Force vs Feed Rate MAL Inc User Manual for CutPro exe 250 a Exp Average Cutting Forces Ex07 CuttingCoef csf gt iol x Exp Average Cutting Forces T Force N 0 10 m d _ O o aD EOS WS Cutting X 0 127172 Options Coord s Zoom Reset Coef s Y 314 029505 Figure 9 8 4 1 Average Cutting Forces result from Example C Click on Cutting Coef s on the toolbar of the window to open Material Editor The cutting coefficients
106. e below C Single analytical A fast analytical stability lobes prediction solved in a frequency stability lobes domain C Multiple analytical Generates stability lobes with axial and radial depths of cut and stability lobes spindle speed c Optimize variable Automatically calculates pitch distribution at a specific spindle pitch speed for 4 given number of flutes Drilling i Cutting coefficient Automatically identifies the cutting coefficients based on files identification defining 4 v and cutting forces Simulation Mode Output Figure 2 1 15 Cutting Coefficient Identification mode is selected in General tab of the 212 Axis Milling module MAL Inc User Manual for CutPro exe 42 This mode enables you to identify cutting coefficients of a user defined material Material cutting coefficients have important roles in the process simulations in CutPro and should be identified accurately for the sake of accuracy of the simulation results CutPro has already material coefficients data available for some materials If the workpiece material is not in the material list you need to identify the cutting coefficients before proceeding the simulation This requires 6 7 force measurement tests with the tool and workpiece material you wish to cut at a constant depth of cut and cutting speed but varying feed rates After the tests are completed you load the force data files into CutPro It processes the data and generates the cuttin
107. e following Average method This is the only cutting coefficients calculation method currently available based on an average cutting coefficients model experimental cutting forces from milling Geometrical This is not currently available average method File File containing data on experimental cutting forces name at the feed rate specified Experimental cutting force data file must be in ASCII format as follows MAL Inc User Manual for CutPro exe 127 First column is Fx Second column is Fy Third column is Fz The experimental cutting force length should be exact number of revolution 1 2 or more Unit is Newton Feed Feed rate for the current experimental cutting rate forces file Back Go to the previous File name Feed rate Delete Delete the current File name Feed rate Next Go to the next File name Feed rate 3 1 10 TEMPERATURE PROPERTIES TAB CutPro Untitled csf Fie Simulation Results Tools Window Help Des E ks New Open Save Properties Run Lee Run Temp E i Plot All in Modal Mal F MalD fs SpindlePra Animation Machining Simulation Properties Process Temperature lt gt ae p y Hide Properties Back Mext Tabs Cancel Ok General Machine amp Tool Workpiece Cutting Conditions Workpiece maternal Aluminum 4L 706 16 Cutter material Carbide Simulation properties Divisions along chip thickness Ny aa Angular divisio
108. e7N m for both directions Click Next to go to the Workpiece Material tab Select Average cutting coefficient mode and choose Aluminum AL7 075 T6 from the material drop down menu Click Next to go to the Workpiece Structural Flexibility tab For the purpose of this example the workpiece is assumed to be rigid Click Next to go to the Cutting Conditions Milling Mode tab The parameters to be entered are exactly the same as in the previous section The Spindle Speed is specified to be 6000RPM and the number of revolutions is entered as 15 The sampling frequency scale can be entered as 10 Note that the Material Removal Rate and the Surface Speed are dependent on the other parameters entered Click Next to go to the Cutting Conditions Other Parameters tab No other parameters can be entered Click Next to go to the Temperature Properties tab Enter the number of divisions along chip thickness and divisions along the tool It is recommended that at least 10 divisions be used for more accurate results Enter the number of angular increments on the tool and the associated tolerance F MAL Inc User Manual for CutPro exe 292 Select the Maximum temperature history along the full cutter rotation to find the maximum temperature in the process Click Run Temp to run the temperature simulation Click Results gt Plot gt Maximum Temperature History Along the Cutter Rotation a Maximum Temperature History Along the Cutter Rotation Ex13
109. eat S When this button is pressed you may use the left mouse 2am button to click and drag a zoom rectangular on the graph Use the right mouse button to go back to the previous view 6 2 2 5 RESET a This button resets the original scale of the graph It Reset zooms out to the minimum magnification so the entire graph can be viewed MAL Inc User Manual for CutPro exe 199 6 2 2 6 REAL E When this button is clicked real values are displayed on Real the graph 6 2 2 7 I MAGI NARY H When this button is clicked imaginary values are Imaginary displayed on the graph 6 2 2 8 MAGNI TUDE M When this button is clicked magnitude real imaginary eS values is displayed on the graph 6 3 SELECTING FRF FILES Simulation Mode Measurement Point 1 Location z mm 0 000 FRF File m s M Browse f Bar 1 D Plane 2 1 FRF Type TestFR Fes 11 trk f Acceleration File Type fasc Frf C Displacement a Delete Insert ct Modal Model Frequency Range Hz 100 to 5000 C Complex Modes Impact Pair i Clear Defaults f Real Modes Gain Constant i Cancel Figure 6 3 1 Select FRF Files window 6 3 BROWSING THE FILES Here you define frequency response functions FRFs at various points along the axial depth of cut For each point you must specify its location as measured from the tool tip or from the workpiece and the corresponding frf file Select
110. ed Steel H55 Example Material Figure 3 1 42 User defined material list in Machine amp Tool Cutter Properties tab The following functions are available in order to edit materials Table 3 1 7 Buttons of Select a cutter material New Create a new user defined material and display it in the Material Editor window View View fixed materials or edit user defined materials the specifications of currently selected material in the Material Editor window Copy Create a copy of the currently selected material and display it in the Material Editor window Delete Delete the currently selected material This button is only enabled for user defined materials When you click on the New button in Figure 3 1 40 the following Material Editor window pops up Please scroll down in order to enter all the specifications After you enter the parameters click on the Save button to save the values you entered or click on the Cancel button to cancel and close the Material Editor window without saving the parameters MAL Inc User Manual for CutPro exe 79 Material Editor File Properties Mame No name Thermal conductivity paimk Density gcr Save Cancel Figure 3 1 43 Material Editor window for User Defined Materials If you click on the View button in Figure 3 1 40 the following Material Editor window shows up Material Editor File Properties Hame Carbide S Thermal conductivity paimk
111. edge force coefficient N mm Kae axial edge force coefficient N mm Ktc tangential shearing coefficient N mm 2 Krc radial shearing coefficient N mm2 Kac axial shearing coefficient N mm2 MAL Inc User Manual for CutPro exe 10 5 Appendix B5 High order force Equations dF K dS K h dz dF K_ dS K h dz dF K dS K h dz K K h K h K h K K re2 h K 22 he K a h K 20 K ae Keer h Ke2 h Kaat A Kyo K K o hK K o h K a htK o K rc2 h K o2 he K a h K 20 K wo h Kae h K acht Kao dFt differential tangential force N dFr differential radial force N dFa differential axial force N dS differential cutting edge length mm dZ differential axial depth of cut mm h chip thickness mm Ktei polynomial tangential edge force coefficients Krei polynomial radial edge force coefficients Kaei polynomial axial edge force coefficients Ktci polynomial tangential edge shearing coefficients Krci polynomial radial edge shearing coefficients Kaci polynomial axial edge shearing coefficients i 0 1 2 Kte tangential edge force coefficient N mm Kre radial edge force coefficient N mm Kae axial edge force coefficient N mm Ktc tangential shearing coefficient N mm 2 Krc radial shearing coefficient N mm2 Kac axial shearing coefficient N mm MAL Inc User Manual for CutPro exe 267 model 11 INDEX A ADVANCED MILLING 30
112. ement sensor shaker and force sensor and displaying the results in any format of a F X F or F F Has an expert system that automatically investigates the quality of the measurement and leads you with the next step to take until all of the measurements meet certain quality requirements This reduces the inexperienced user s faults in the measurements and provides consistency in the measurement quality Displays the Input and Output signals in the time domain the Magnitude amp Phase and Real amp Imaginary frequency response functions the Power Spectrum and the Coherence of the measurements Saves the measurement data in a standard format frf that can be directly used in the process simulation modules in CutPro or other software packages 1 2 6 MALDAQ MalDAQ is a highly versatile PC based data acquisition and analysis software MalDAQ can be used to measure cutting forces vibrations acoustics and sensor signals The program was developed and tested for the National Instruments DAQCard 6062E DAQCard Al 16E 4 PCMCIA cards used in notebook computers and the PCI MIO 16E 4 a PCI card used in desktop computers The software is also compatible with many analog data acquisition devices that are available from National Instruments MalDAQ has the following features Max 500 kHz sampling frequency Up to 8 channel data acquisition Logging and streaming data to disk until the disk gets full MAL Inc User Manual
113. emp to run the Temperature Simulation A DOS window similar to the window above will be displayed When the MAL Inc User Manual for CutPro exe 158 Simulation is done the DOS window is closed and the results are loaded automatically If you want to abort to simulation before its completion press the Stop Temp button Please refer to Chapter 8 Example Files for examples of Simulations MAL Inc User Manual for CutPro exe 159 5 VIEWING RESULTS Once you have run a simulation one or more results are produced depending on what you have selected on the Output Tab and the type of simulation you have run All of the available results are listed under the Results gt Plot menu ji CutPro Ex01_ Single Analytical csf File Simulation Results Tools Window Help Flot All Ctrl F E Plot New Ope Export T i Modal MalTF MalDAQ Spinc Run Temp Plot All Machining Si Report Ctrl T Process g al Clear Results gt Hide x y A TES Back Next Tabs Cancel OK 5 1 VIEWING ALL RESULTS Select Results gt Plot All or clicking Plot on the main window toolbar 5 2 VIEWING INDIVIDUAL RESULTS Select an individual result under Results gt Plot The available output results are as follows Only certain results will be available depending on the type of simulation you have run MAL Inc User Manual for CutPro exe 160 5 3 RESULTS WINDOW
114. ency of the tool flexibility in the Y direction whereas the 400Hz smaller peak is due to the tool during the cut Note that spindle speed is at 6000RPM meaning that the spindle rotates 100 times per second Since there are 4 flutes on the tool the flutes would hit the workpiece at 400Hz 8 2 3 SIMULATING THE MILLING PROCESS AT 14300 RPM This section of the example is contained in the example file Ex03_SingleTime_14300_6mm csf The steps in this section are exactly the same as the steps in the previous section MAL Inc User Manual for CutPro exe 242 The tool vibration simulation obtained for 8000RPM shows only one peak at around 533Hz which is the frequency at which the flutes hit the workpiece 4 FFT Tool Vibration EX03_SingleTime_8000_7mm csf O x Tool Vibration FFT Deflection mm 1000 2000 S000 4000 spod 00d Frequency Hz oe o M ke EOS ws 7141 549334 Options Harmonics Coord s zoom Reset Y 0 015031 Figure 9 8 2 4 Tool vibration at 8000Hz in frequency domain 8 2 4 OPTIMIZING VARIABLE PITCH This section of the example illustrates how to obtain the optimum variable pitch in order to run the process at 5000RPM and an axial depth of cut of 5mm with stability The following steps are contained in the example file Ex05_Optimumpitch_5000 csf Select the Advanced Milling module select Optimize Variable Pitch mode Click Next to go to the General Output tab Note that no selections can
115. escribed in the following table Table 3 1 1 Animation Options of Milling Animation Starting revolution Revolution number at which you start saving animation data Make the numerical value consistent with the Number of revolutions under the Cutting Conditions Milling Mode tab End revolution Revolution number at which you stop saving animation data Make these numerical values consistent with the Number of revolutions under the Cutting Conditions Milling Mode tab Starting level The simulation divides the depth of cut MAL Inc User Manual for CutPro exe 64 into a number of levels depending on the cutter type and cutting edge geometry This value is the level at which to start saving animation data End level The simulation divides the depth of cut into a number of levels depending on the cutter type and cutting edge geometry This value is the level at which to stop saving the animation data 3 1 2 2 STABILITY LOBES IN TIME DOMAIN In the General Output tab of the Stability Lobes in Time Domain mode all of the options are disabled CutPro automatically saves the Stability lobes data which includes axial depth of cut and spindle speed values corresponding to the critically stable state of the milling process JE Stability Lobes Time Domain Untitled csf Stability Lobes Time Domain E E D yu oO OL T O 4000 BOOO apog 10000 12000 Spindle Speed rpm yl BSS 1 3197E 04 Options Coord
116. ew Open Save Propertes Run Run Temp Machining BEST eaten ml apes sais Process WWorkpiece lt gt tial X vo Matenal Back Next Tabs Cancel OK General Machine amp Tool Work piece Cutting Conditions Temperature Select a workpiece material Material Type Maternal Hame User Defined Maternals Aluminum Allo E Grey Cast Iron Heat Resistant aa High Alloy Steel MDF Layer 1 Milling Slotting 14 rake 2 High Copper Alloy MDFlLayer 2 Milling Slotting 14 rake 2 Low Alloy Steel MOF Layer 3 Milling Slottirig 14 rake 2 EJ MAL Materials MOF Plunge Turning 0 rake angle MDF Plunge Turning 15 rake angle Nodular Cast Iron MDF Plunge Turning 30 rake angle J Stainless Steel F20 Steel Ballend mill calibaretd with axial deptt Steel Casting Titanium Alloy TiAl Rake Angle 5 deg s40 ich Titanium Alloy Titanum Alloy TIEA Rake Angle 5 deg 340 Unalloved Steel Selected Workpiece Material Aluminum AL O75 T6 150 HB Average milling cutting co Material Structural Flexibility Figure 3 1 69 Workpiece Material tab The Workpiece Material tab allows you to select or define the material of the workpiece 3 1 6 1 DEFI NE A WORKPIECE MATERIAL In the Workpiece Material tab you can select the workpiece material from the list or define a new material with its specifications such as composition density thermal conductivity specific heat capacity Young
117. g Mode tab Face milling is selected in this figure 3 1 8 2 BALL ENDMI LL The cutting parameters are the same for this tool as the regular cylindrical one However there is no selection for milling mode and the width of cut is defined through Workpiece width w and Y Offset y MAL Inc User Manual for CutPro exe 121 v CutPro Untitled cst File Simulation Results Tools Window Help Ce oe AD ve E 7 New Open Save Properties Run Run Temp Plot All Modal MalTF Malb4Q SpindleProa Animation Machining EDIE tse Eo Process Cutting Conditions lt x gt x sf Milling Mod Hide HANG ACG Back Next Tabs Cancel OK General Machine amp Tool workpiece ulting Conditions Temperature Spindle direction Clockwise Counterclockwise C Feedrate mmflute 0 05 Codais Canc C Spindle speed APM 5000 005 Axial depth of cut a mm 85 Humber of revolutions 0 Sampling frequency scale 0 Maternal removal ratelk ert mirn 42 355 Surface speed m min 299 237 Figure Cutting Conditi Se ee ra a Workpiece width i mm 19 05 Y offset y mm 15 525 R Drilling Hilling Advanced Prediction of cutting Milling Mode Other Parameters forces Figure 3 1 95 Cutting Conditions Milling Mode tab The relation between the width of cut and w and y can be shown as follows If y gt R W WOC W4 R y If y lt R WOC w where R and WOC are the ra
118. g Spindle speed N RPM 5000 Radial Depth of Cut ar mm 3 Radial Depth of Cut Increment 0 1 rrr Cutter Rotational Increment 0 1 Humber of Revolutions a Surface speed mmiri 391 765 Figure Plunging conditions Cutting Conditions Figure 3 2 12 Geometry of Cut Plunge Milling with Pilot Hole MAL Inc User Manual for CutPro exe 137 Plunge Milling Simulation Properties Cattig Conditions lt gt mei x y Back Wexk Tabs Cancel OK Cufing Conditions General Machine amp Tool Work piece Cutting Conditions Geometry of Cut E pp Tee lle Feedrate f romflute 0 075 C Plunge Milling with Pilot Hole Spindle speed N APM AOU Radial Depth of Cut Increment mm Number of A evolutions 0 1 Cutter Rotational Increment 0 1 4 391 765 Surface speed m min Figure Plunging conditions Cutting Conditions Figure 3 2 13 Geometry of Cut Side Plunge Milling MAL Inc User Manual for CutPro exe 138 139 3 3 TURNING MODULE Cece GENERAL SIMULATION MODE TAB Turning Simulation Properties Gener lt gt l 1 x 7 Simulation Mode aai Back Mext Tabs Cancel OK General Machine amp Tool workpiece Cutting Conditions Temperature f Static analysis Predicts static cutting forces Analptical stability Use this mode to simulate stability lobes within a narrow speed lobes range Cutting coefficient Automatically identities the cutting coeff
119. g coefficients for you Then the cutting coefficients are saved in the user defined material list in order to be used in the simulations The details of the procedure are explained in Section 3 1 10 6 Cutting Coefficient Identification Sample result window of cutting coefficient identification mode is given in the following figure Sample Result Exp Average Cutting Forces Force N Feed Rate mm flute Figure 2 1 16 Sample Result window of Cutting Coefficient I dentification mode MAL Inc User Manual for CutPro exe 43 Lild PLUNGE MILLING MODULE CutPro Untitled csf File Simulation Results Tools Window Help O E MA Mer Open Save Properties Run Machining Process Figure 2 1 17 Plunge Milling module CutPro simulates the action of plunge milling with this module The plunge milling module contains three simulation modes static analysis of a plunge milling operation dynamic simulation of a plunge milling process and stability lobes prediction 2 1 2 1 STATIC ANALYIS OF A PLUNGE MILLING OPERATION W CutPro Untitled csf Fie Simulation Results Tools Window Help T 5 E Lea m Oth f Wi ae kai New Open Save Properties Run Run Temp Plot All Modal M Machining Process Gereral lt gt M xX y Hide Simulation Mode Back Mext Tabs Cancel OK oe General Machine amp Tool Workpiece Cutting Conditions Simulates cutting forces spindle power
120. ial data is only for your benefit as an information Select the depth of cut in cutting conditions page Now you are ready to enter the measurement files when you click next again MAL Inc User Manual for CutPro exe 105 2 Select the force measurement files which can be text or binary mdq files which can be indicated from the file type as shown below a CutPro Untitled csf Seles File Simulation Results Tools Window Help a i za K D m It ww 4 ry eas AQ SpindleFro VirtualiWc Anime New Properties Run T Modal MalTF Mal Open Save Flot All Run Temp Machining perties Process Cutting Conditions gt Pext x y Cancel OK Hide Ofer Parameters Back au File Browse Look in O MALDAG Cutting Forces amp amp Fee id 55000_D2_F0075 mdq ah A S5000_D2_FO100 mdq My Recent A S5000_02_F0125 mdq Documents ak s5000_D2_F0150 mdq Ah S5000_Db2_FO175 mdq km i 55000_D2_F0200 mdq Desktop My Documents Drilling ra My Computer Cai My Network File name ExpCutForce_1 25 2 bet Places Mapan File mdq Cancel CutPro Simulation Files txt ee Data Files dat MalDAG File mt MalDAG File md Files of type Opened file C CutPro 3 Select the correct measurement file and click Open to upload to CutPro M
121. iations of the flutes When you check the box Run out File window shows up Figure 3 1 32 Run out File window Table 3 1 3 Buttons on Run out File window Open Open an existing run out cro file Edit Edit the currently selected run out file This brings up the Run out Editor window Create Create a new run out file This brings up the Run New out Value Editor window OK Select the current file and close the window Cancel Close the Run out File window and revert to the previously selected file gt Run out alue Editor l iOj x File Edit Units The unit of the run out values is Micrometer HO Level mma Flute 1 Flute 2 Flute 3 Flute 4 D0 oT ee cd a Figure 3 1 33 Run out Value Editor window In Run out Value Editor window you define deviations of each flute at a series of axial locations along the depth of cut The Run MAL Inc User Manual for CutPro exe 74 out Value Editor window consists of a table The first column lists the axial locations at which deviations are measured and the other columns correspond to the deviations of each flute Menu commands on the Run out Value Editor window are given in the following FILE COMMAND Run out Yalue Editor 5 x File Edit Units Open Chrl O The unit of the run out values i Micrometer Flute 3 cave brl4 5 PE Flute 4 Exit Ctro Figure 3 1 34 File command on Run out Value Editor
122. icients based on tiles identitication defining agential Radial and Feed cutting forces Simulation Mode Output Figure 3 3 1 General Simulation Mode tab of the Turning module This tab allows the user to select the simulation mode Only Static Analysis is available for the time being MAL Inc User Manual for CutPro exe 140 3 3 2 GENERAL OUTPUT TAB Turning Simulation Properties General Ouipui lt gt e v z Back Next Tabs Cancel Ok General Machine amp Tool Work piece Cutting Conditions Temperature Check the output you want to save J Cutting forces J Uncut Chip Area Static deflections J Spindle power amp tongue Surface finish P Tool vibrations Simulation Mode Figure 3 3 2 General Output tab of the Turning module This tab allows the user to select the outputs to be made in the simulation If an item is not selected its corresponding plot s will not be available for viewing and it will not be saved in the simulation file mw MAL Inc User Manual for CutPro exe 141 Gre ne MACHINE amp TOOL CUTTER PROPERTIES TAB Turning Simulation Properties Machine amp loos iul amp y Toot Properties au H Back Next Tabs Cancel OK General Machine amp Tool Work piece Cutting Conditions Temperature Select cutting tool Carbide Hew Import Delete Turning Side cutting edge angle yt p 5 Side Rake angle
123. iew edit the parameters defining the current simulation 1 3 4 3 RESULTS V CutPro Untitled csf File Simulation Results Tools Window Help C Flot All Ctrl P La Plot i Mew Op Export Run Temp Plot All Machining si Report CErI T Process _ Clear Results aK gt Hide x yl Back Mext Tabs Cancel DK General Machine amp Tool workpiece Cutting Conditions Figure 1 3 4 Results menu in CutPro Table 1 3 4 The drop down menu of Results command Plot All Plot all simulation results Plot Allows you to select a simulation result to plot Export Brings up the Export Results window Select a result set from the drop down list then specify the ASCII text file txt to which you want to export it You can either type the name of a text file in the box provided or find an existing file to write over by pressing the browse button Report Brings up the Reports window which summarizes the simulation conditions such as cutting conditions properties of cutter and workpiece and results Clear Results Delete all results This will disable the Results menu You must run a simulation in order to generate new results MAL Inc User Manual for CutPro exe 21 M CutPro Untitled csf File Simulation Results Tools Window Help Plot All 1 C Hew Op Export Machining Report Process Clear Results Ati i fla Cutting Forces Cutting Force Y Cutting F
124. ile Rigid F Open Bat ti d EF fil E i Y transfer function file Rigid P 0 hodalresidue data files Wpen ait Z transfer function file Rigid P Dinamie parameters Apen Bain TF wou select a file type other than ASC fre the file will be converted to ASCII and saved with the Material Figure 3 3 6 Workpiece Structural Flexibility tab This tab allows you to modify the structural flexibility of the workpiece Note that this version of CutPro does not yet support the dynamics of the workpiece for turning processes uw MAL Inc User Manual for CutPro exe 145 3 3 7 CUTTING CONDITIONS TAB Turning Simulation Properties q Catt CON ditions gt se f Hide C ufing Conditions Back Next Tabs Cancel CK General Machine amp Tool Workpiece Cutting Conditions Temperature Feedrate c mare 0 185 Surface speed M m min 250 Spindle speed M RPM 1808 579 Diameter of the workpiece O mrm 42 65 Depth of cut fal mm 0 675 Length of cut L mm ol Number of revolutions 0 sampling frequency scale 0 Cut Geometry Cutting Conditions Uther Parameters Figure 3 3 7 Cutting Conditions tab of the Turning Module This tab allows you to enter the cutting conditions Feed rate Spindle speed Depth of cut and Surface speed 2 3 0 CUTTING CONDITIONS OTHER PARAMETERS There are currently no other parameters that can be defined
125. includes its own modal analysis software which may be run from the Tools menu in the Main CutPro Window The software reads either an acceleration or displacement frequency response function FRF file and generates modal parameters which may be used in CutPro to define the Machine and Workpiece dynamics Fi 3D Modal Analysis Untitled 7 oO x H8 R Yt el oles Mode f Shape Frequency Hz Residue Re m Residue Im mo Modal Stiffness Mass kg Measurement 1 1 0000e00 o 0000e 014 B OO00e 01 4 0000e 014 2 0000e 01 SUREN Magnitude mM 03 o4 O05 Frequency Hz je A ai EOS s G H mM x 3146 027917 Options Modes Cursor zoom Reset Real Imaginary Magnitude Y 1 2102E 06 FAF file opened C ACutPros Programs 00001 tmp a Figure 5 3 1 Modal Analysis window 6 1 3D MODAL ANALYSIS MENU File New Create a new 3D modal analysis file mod Open Open a 3D modal analysis file mod Save Save the current mod file Save AS Save the currently opened modal analysis file under a different name Select Open Frequency Response Function Transfer FRF Files Function measurement files from the Select FRF Files window Please see Section 6 3 Save Bring up the standard Windows Save dialog allowing MAL Inc User Manual for CutPro exe 194 Para you to save the current modal parameters for use in meters CutPro Print Print the currently displayed modal graph Printer
126. ion of CutPro does not yet support the and tool dynamics of the workpiece for turning processes MAL Inc User Manual for CutPro exe 143 3 3 5 WORKPIECE MATERIAL TAB Turning Simulation Properties E Workpiece x gt fo x v4 Hide Material Back Mext Tabs Cancel OK General Machine amp Tool Work piece Cutting Conditions Temperature Select a workpiece material Aluminum 6061 T6 amp Kennametal CPMT 32 52 Kral Based on average force measurements This is the simplest Mechanistic model which requires the least esperimental measurement Orthogonal to oblique Based on orthogonal cutting tests Extensive experimental cutting transformation tests must be conducted applicable to any tool geometry Cutting Coefficient Model Material Structural Flesibility Figure 3 3 5 Workpiece Material tab of the Turning Module This tab allows you to specify the material of the workpiece Please refer to Section 3 1 6 WORKPIECE MATERIAL TAB Advanced Milling Module for detailed description F MAL Inc User Manual for CutPro exe 144 3 3 6 WORKPIECE STRUCTURAL FLEXIBILITY TAB Turning Simulation Properties E i Workpiece Structural Flexibilit gt Hil v Back Mext Tabs Cancel OK General Machine amp Tool Work piece Cutting Conditions Temperature Workprece Model 0 Rigid 0 Dynamic vibrations t Static defections Workpiece Dynamics bode 4 transfer function f
127. ip TINIGCKNCSS saseccecseceatavenawcwas cas sucienseewsesnsesesweucesssesnnesnewsneesssees 255 9 5 Appendix A5 Geometric Figures for Tools 256 MAL Inc User Manual for CutPro exe 9 5 1 General Tool Geometry Parameters Figure 0008 256 9 5 2 Geometry tYp s sssssassssnssassnasananesosanesosanasesnnsanane 257 9 5 3 Flute type figUre sssssssssnsnsnsnsnnennnnnnnnnnnnnnnnnnnnnnnnne 258 9 5 4 Cutter amp Insert Coordinate SySteMs s ssessssssssssssssns 259 TO Append D sosissionen EEA 262 10 1 Appendix B1 Orthogonal to oblique cutting transformation model EquationS sssssnnnnnnnnnnnnnnnnnnnnnnnn 262 10 2 Appendix B2 Bi linear force model Equations 263 10 3 Appendix B3 Exponential chip thickness Equations 265 10 4 Appendix B4 Semi mechanistic model Equations 266 10 5 Appendix B5 High order force model Equations 267 LL PIWDEA seecccseresstnosercecccecventuctenersencesanseccesaeseaceeus 268 MAL Inc User Manual for CutPro exe 1 INTRODUCTION CutPro is an analytical and time domain machining process simulation and Spindle design software package developed for off line process optimization It can be used as a learning tool as well as an optimization tool for process planners and machine tool builders to increase production and stability performance of the spindle respectively Furthermore CutPro assists you in the tool and spindle design processes for optimum productiv
128. ity in a controlled environment 1 1 INSTALLING CUTPRO Minimum System Requirements Windows 98 Me NT 4 0 2000 or XP Pentium III 450 MHz processor 128 MB RAM 120 MB free hard drive space SVGA at 800x600 256 Colors Recommended System Requirements Windows Me NT 4 0 2000 or XP Pentium III 800 MHz or faster 128 MB RAM or more 200 MB or more free hard drive space SVGA at 1024 x 768 True Color amp In order to use the FULL version of CutPro you must have a CutPro hardlock security key and a valid password for each module you wish to use You will be prompted to enter these passwords the first time you run CutPro To obtain your passwords please contact MAL Inc 1 1 1 INSTALLATION INSTRUCTIONS Insert the CD labelled CutPro into your CD ROM drive From the Start menu select Run Type D SETUP or substitute the appropriate letter of your CD ROM drive for D You can directly run the installation from CD by clicking CutPro exe Follow the instructions on the screen MAL Inc User Manual for CutPro exe ie ee 10 OLDER VERSION OF CUTPRO ALREADY INSTALLED Before installing CutPro you should uninstall any older versions already installed on your computer and remove the software key from the computer Any simulation files e g mil dat you created will not be removed Follow the steps to remove the existing CutPro in your computer Under the Start menu select Settings gt Cont
129. l Dimensions Measurement Point 2 Limm 10 p ptimi2ation Tool Shank Diameter D2 rim 20 Min Tool Overhang Length a mm B Cutter Length L1 mr 35 Max Tool Overhang Length 0 mm Cutter Diameter O 1mm j G Maz Spindle Speed 0 Pm D amping A atio RT 0 03 Aun Optimization Figure 6 9 29 Tool Length Tuning Browse Tool Holder Spindle Project The procedures to optimize the tool length tuning 1 Click the button Browse Tool Holder Spindle Project then the open file dialogue box will pop up MAL Inc User Manual for CutPro exe 228 Ci ReceptanceCoupling a ajx a se Open Save Exik I Tool Dimensions E Open EJEJ a Identification of Tool Tool Holder Interface kai Look in Tool ToolHolder_ Fc rc My Recent Documents G Browse Tool Holder Spindle Project r Optimization Min Tool Oyverhang Length 45 mm Mas Tool Overhang Length 55 mm Max Spindle Speed 5000 rpm Aun Optimization f Piy Network File name foo Places Files of type Receptance Coupling Files rch w Cancel Figure 6 9 30 Tool Length Tuning open a Tool Holder Spindle Project 2 3 Select a project file in the dialogue box then click the button Open After the project file is loaded the Run Optimization button is available A user can click it to run the optimization engine after he she changes the optimization conditions CE
130. l column and fixture Accepts FRF measurement files in MalTF ASCII HP SDF UFF file formats Easy to use for non vibration experts lale MALTF MalTF is a versatile transfer function measurement program which has been tested for the National Instruments DAQCard 6062E DAQCard Al 16E 4 PCMCIA cards used in notebook computers and the PCI MIO 16E 4 a PCI card used in desktop computers The transfer function measurement is performed with impact hammer tests The results from these tests can be displayed in different formats and saved to disk to be imported into modal analysis software After performing a series of impact hammer tests the resulting transfer function will be displayed on screen Various display options can be changed during and after the impact hammer tests to alter the way in which the information is displayed on the screen The transfer function itself can be viewed in Eny MAL Inc User Manual for CutPro exe 14 magnitude phase mode or alternately in its real and imaginary components The linear part s of the transfer function can be viewed in time domain or as a frequency spectrum In addition the transfer function can be saved in binary format and opened with the all measurement settings at a later time MalTF is extremely fast and very easy to use and has the following features Allows measurement in multiple directions Allows the use of different output sources i e accelerometer displac
131. le Click the Play Stop button to play or stop the animation Alternately you can use the large scroll bar to manually scroll through the animation Use the Up Down Arrows to change the Level i e axial position along the depth of cut You can also change the Speed of the animation using the small scroll bar Under the Units menu you can choose to display either Metric or Imperial units of measurement If you open the Milling Animation program and then run a different simulation under CutPro and would like to see the new results click the Reload button MAL Inc User Manual for CutPro exe 234 de Milling Animation o x Units p p E 6 all Speed 4 aia Reload Play Zoomin Zoom Out p 000 Time 0 00000000 0 024s Leve 0 H Figure 6 9 1 Milling Animation Window MAL Inc User Manual for CutPro exe 235 3 EXAMPLES 8 1 EXAMPLE FILES The following example files are provided with CutPro They can be found in the Examples directory under your main CutPro directory To open an example file select File gt Open or click the Open button in the main CutPro window 8 1 1 Ex01_SingleAnalytical csf Single Analytical Simulation for Regular pitch cutter This is a stability lobe simulation for a cylindrical end mill 8 1 2 Ex02_SingleTime_6000rpm_3mm csf Single time domain simulation for cylindrical cutter in chatter area Spindle speed 6000 rpm 3 mm depth of cut Sues Ex03_SingleTime_14300_6mm csf
132. le Click Open to Browse for the desired frf file the file type can either be Acceleration or Displacement By pressing Gain a gain constant can be applied to the selected frf file and a new file with a _new extension will be saved by default For example TestFRFRadial frf will be saved under TestFRFRadial_new frf if a gain constant is applied amp Note Dynamic vibrations only apply to the radial direction amp Note Structural Flexibility does not apply to Static Analysis MAL Inc User Manual for CutPro exe 152 3 4 5 WORKPIECE MATERIAL TAB CutPro Untitled csf File Simulation Results Tools Window Help OD ot Of A New Open Save Properties Run Modal Machining Boring Simulation Properties Process P kForkpiece Maternal lt gt Hige Ee a Back Next Tabs Cancel OK General Machine amp Tool Work plece Cutting Conditions Temperature Select a workpiece material Maternal Type Maternal Hame User Defined Materials Aluminum Alloy Aluminum Allo Heat Resistant 4L 6061 T6 95 HB ea High 4lloy Steel E AL r050 T 74510140 HE Ea Low 4lloy Steel a Titanum Alloy Selected workpiece Maternal AL 6061 T6 95 HB Material Figure 3 4 5 Workpiece Material tab in the Boring Module This tab allows you to select the workpiece material You may define new materials with different force model simulation modes Mechanistic or Orthogonal to Oblique Cutting Transformation
133. lece Cutting Conditions Select tool material Carbide Hew MEN Copy Cutter parameters Insert onentation parameters Current insert Radius of insert center r mm E A Relief angle Cl f Ype square 1 Radial rake angle 0 Edit t hype __Editinsert type Axialtake angle f 0 Lead angle Y T 10 Tool Type Tool Properties Figure 3 2 7 Machine amp Tool Tool Properties in Plunge Milling This tab allows you to select or define tool material and enter tool properties In this tab only the necessary parameters for the selected tool type are enabled 3 2 4 1 SELECT A CUTTER MATERI AL For selecting and defining a tool material refer to 3 1 4 1 Select a Cutter Material MAL Inc User Manual for CutPro exe 3 2 4 2 TOOL PROPERTIES Cutter parameters lnsert onentation parameters Curent insert 1 Level of insert center mm 0 Radius of mser center r mm G Relief angle Cl i Type Square 1 Radial rake angle 0 Edit t type _ Editinsettype Mieco ZZ Copy across flutes Lead angle YT 10 Lag angle 4 T Radial offset angle 0 135 Figure 3 2 8 Tool Properties in Machine amp Tool Tool Properties tab In the Machine amp Tool Tool Properties tab you can define the type of insert and parameters of each flute You can choose No Insert Square Insert or Rhombic Insert and define geometrical par
134. lue F MAL Inc User Manual for CutPro exe Simulation Properties Cutting Conditions s ras lt gt fuel Y Milling Mode Back Next Tabs Cancel OK General Machine t Tool Workpiece Cutting Conditions Temperature Spindle direction Clockwise Courter clockwise r Feedate mmithae 0 05 m Spinde speed RPM 4393 998 p Miling Mode Ayial depth of cut La men 5 C Downmiling Number of revolutions la Upmiling Sampling frequency scale C Stotting Material removal ratel em min C Facemiling Surface speed m min or Radial vadth of cut ibl ren 3 929 118 Figure 3 1 92 The Cutting Conditions Milling Mode tab Up milling is selected in this figure 3 1 8 1 3 SLOTTI NG As the tool has full contact with the workpiece for this milling mode Radial width of cut is equal to the diameter of the tool and text box for radial width of cut is not available MAL Inc User Manual for CutPro exe 119 Simulation Properties Cattag Conditions MANAG Mode Back Next Tabs Cancel OK General Machine amp Tool workpiece Cutting Conditions Temperature Spindle direction Clockwise Counterclockwise 0 Feearate mmute 0 05 Spindle speed AFM 4999 955 Milling Mode Axial depth of cut a mm 5 Number of revolutions aol C Down miling EC Up millirig Sampling freque
135. lunge milling Sas CUTTING CONDITIONS TAB In the Cutting Condition tab you can define the geometry of cut and cutting parameters which include feedrate spindle speed radial depth of cut increment cutter rotational increment and number of revolutions Depending on the simulation mode static analysis dynamic Simulation analytical stability lobes and the type of tool symmetrical or unsymmetrical selected three types of geometry of cut may available Plunge Milling Plunge Milling with Pilot Hole and Side Plunge Milling MAL Inc User Manual for CutPro exe Plunge Milling Simulation Properties Cattng Cosdiions me 3e Cutting Conditions lt gt Hide v Back ext Tabs Cancel OK General Machine amp Tool Work piece Cutting Conditions Geometry of Cut Feedrate f romFlute Plunge Milling with Pilot Hole C Side Plunge Milling Spindle speed N APM Radial Depth of Cut ar mrm 5 Radial Depth of Cut Increment mm Cutter Rotational Increment 7 Number of Revolutions Surface speed m min 391 765 Figure Plunging conditions Cutting Conditions Figure 3 2 11 Geometry of Cut Plunge Milling Plunge Milling Simulation Properties Latting Conditions lovee Cutting Canditians lt gt Hide vw Back Mext Tabs Cancel OK General Machine amp Tool workpiece Geometry of Cut o A Plunge Milling Feedrate f mmflute 0 075 amp Plunge Milling with Pilot Hole C Side Plunge Millin
136. m fan Tool p datance tom certerkne of beng bar Flim 22 Side cuting edge ange FT 5 Side rake ange a I T fp Back rake ange iall fp Tool Nose Radus A Jimm i8 This parameter i ignored for Mechanistic Model Riadalruncutle jinn 7 Feed nunga fep bm fo Figure 3 4 3 Machine amp Tool Tool Properties tab This tab allows you to create and select among different cutting tools to simulate Some properties are illustrated in the following diagram MAL Inc User Manual for CutPro exe 150 Figure 3 4 4 Geometry of a Boring tool amp Note The first four properties listed in the window are not available to the Analytical Stability Simulation MAL Inc User Manual for CutPro exe 151 3 4 4 MACHINE amp TOOL STRUCTURAL FLEXIBILITY TAB Siruclwal Fiexibilily a Tried x wv Cane OF Genet Machine Tod Workpiece Cutting Condition Tempershure Machine amp Toni Hode FRF Type l Hoda larmia Feed Acceleration pw eN e a Dupisermen wH C E R Frequency Range He 50 lo S000 Gan Constan f The FAF type it necogresed Irom the ul fle suiomsicaly Radia irante function file Pagid Ts TenFAFAadialht Tangential ranite uncha he Riga Ge Peed hange tuncton iis riged TE pou petect a file bape other than ASCII AlL the fhr vai This tab allows you to input dynamic vibrations of the tool in the radial direction through a measured transfer function fi
137. m Reset Figure 3 1 8 Cutting forces in tangential direction MAL Inc User Manual for CutPro exe 60 Se Chip Thickness Untitled csf Chip Thickness A 0 00 0 05 0 10 Flute 1 Flute Flute 3 Flute 4 un un wv E m E EE Time sec YS ee ce EOS fws 0 210785 Options FFT Coord s zoom Reset v 005975 Figure 3 1 9 Chip thickness for each flute e Tool Yibration Untitled cst Tool Vibration rerni ani Deflection mm Time sec et le ins Options FFT Coord s Fata Reset Figure 3 1 10 Tool vibrations in x and y directions MAL Inc User Manual for CutPro exe 61 Upmilling Surface Finish Untithed csf ioj x Upmilling Surface Finish a g Rimas 0 011 Options See 0 008 Figure 3 1 11 Up milling surface finish Two parameters are shown at the bottom right corner of the window Rmax is the maximum surface roughness and Rayg is the average surface roughness ioj x Spindle Power Instantaneous lt Cumulative Average Power KW il 0 00 0 05 0 10 Time sec w itd kw EOS js x 0 123902 Options FFT Coord s foam Reset t 0 260367 Figure 3 1 12 Spindle power MAL Inc User Manual for CutPro exe 62 gt Spindle Torque Untitled csf spindle Torque Instantaneous aay in lt Cumulative Average asl Att 0 00 0 05 0 10 i E md g m H Tim
138. med to be rigid C Dynamic simulation Simulates cutting forces tool vibrations spindle power and torque in a time domain pas Analytical stability A fast analytical stability lobes prediction solved in a frequency lobes domain Figure 3 2 1 General Simulation Mode tab in Plunge Milling module This tab allows you to choose the simulation mode There are three simulation modes available Static Analysis Dynamic Simulation and Analytical Stability Lobes MAL Inc User Manual for CutPro exe 130 Jill GENERAL OUTPUT TAB Plunge Milling Simulation Properties lt gt fil vo Cu fou i Back Next Tabs Cancel OK Gereral General Machine amp Tool Workpiece Cutting Conditions Check the output you want to save mw Cutting Forces mw Spindle power amp torque Simulation Mode Output Figure 3 2 2 General Output tab in Plunge Milling module This section allows you to specify which results you want CutPro to output in simulation To include a result in the simulation output check the box next to it MAL Inc User Manual for CutPro exe 131 232 MACHINE amp TOOL TOOL TYPE TAB Plunge Milling Simulation Properties Machine amp foo fool Type 1 Hie iv Back Wext Tabs Cancel OK General Work piece Cutting Conditions Cutter type Flutes Number of flutes 2 i Symmetrical tool O C Asymmetrical tool W Run out deviations View Figure 3 2 3 Machine amp Tool Tool
139. mer to acquire the frequency response functions Perform at least 5 10 impact tests to average FRFs Three impact hammer tests are required Direct Transfer Function Measurement at the tool tip TF 11 Figure 6 9 2 Direct Transfer Function Measurement at the tool tip TF 11 Cross Transfer Function Measurement between the tool tip and a point on the blank at a distance L from the toolholder L is recommended to be 10 20 mm TF 12 n L2 Figure 6 9 3 Cross Transfer Function Measurement TF 11 MAL Inc User Manual for CutPro exe 215 Direct Transfer Function Measurement at location L from the tool holder TF 22 Figure 6 9 4 Direct Transfer Function Measurement at location L from the tool holder TF 22 6 9 4 3 IDENTIFICATION USING THE SOFTWARE To start select Identify Tool Holder Spindle Assembly button Tool Coupling Identity ToolHolderfSpindle Assembly C Load Existing ToolHolder Spindle Figure 6 9 5 Tool Coupling 6 9 4 3 1 IDENTIFICATION GEOMETRY PARAMETERS Input the blank tool dimensions and properties used to perform the experiments MAL Inc User Manual for CutPro exe 216 C ReceptanceCoupling Seles Fie Options Help l mi bi lt x ToolHolder Spindle 7 ak gt Open Save Back Next Exit r Tool Dimensions EEE identification O Geometry Parameters Impact Measurements ES Tool Coupling Tool Dimensions Measurement Point 2 Limm ed Tool Sh
140. meters of the tool are entered for the Dynamic Analysis mode of the Plunge Milling module This mode is similar to the static analysis of a plunge milling operation but instead of assuming that the tool is rigid the dynamic parameters of the tool are entered by the user Of course the user can enter parameters for multiple modes in each direction and specify any rigid directions MAL Inc User Manual for CutPro exe 45 2 1 2 3 STABILITY LOBES W CutPro Untitled csf File Simulation Results Tools Window Help oe 2 th amp k Save Properties Run Run Temp Plot All Modal MalTF Mal y Machining Process General gt me Simulation lode Back Wext Tabs Cancel OK Machine amp Tool Workpiece Cutting Conditions C Static Analysis Simulates cutting forces spindle power and torque when tool and workpiece can be assumed to be rigid Simulates cutting forces tool vibrations spindle power and torque C Dynamic simulation 2 u in a time domain Analytical stability A fast analytical stability lobes prediction solved in a frequency lobes domain Figure 2 1 20 The Stability Lobes mode is selected in General tab of the Plunge Milling module This mode is similar to the single analytical stability lobes mode in the 2 axis milling module See Section 2 1 1 3 Single Analytical Stability Lobes 2 2 TURNING MODULE W CutPro Untitled cst Fie Simulation Results Tools Window Help 5 m W Mew O
141. mulation modes available in the 2 Axis Milling module namely single time domain stability lobes in time domain single analytical stability lobes multiple analytical stability lobes optimize variable pitch and cutting coefficient identification Depending on your selection you will be led to enter the necessary parameters on the next tabs in order to complete the simulation You can find more information regarding simulation modes under Section 2 1 2 2 Axis Milling module MAL Inc User Manual for CutPro exe 56 Se E GENERAL OUTPUT TAB The General Output tab allows you to choose the output data you want to save during the simulation To include a result in the Simulation output check the box next to it This tab has different options for different simulation modes W CutPro Untitled csf File Simulation Results Tools Window Help De Mth Dm ye Se Mew Open Save Properties Run Run Temp Plot All Modal Machining ELL EL A ai E Frocess General x gt x T T Oufput Hide UD Back Merk Tabs Cancel OK oh m R General Machine amp Tool Workpiece Cutting Conditions Temperature Milling Check the output data you want to be saved as test files during the simulation I Cutting forces Save milling animation data Animation Options W Tool vibrations M workpiece vibrations starting revolution W Surface finish pnevex gator y M Spindle power
142. n algorithm developed at MAL Inc is used to determine transient temperature variations The program outputs include the chip and tool temperature fields distribution of the rake face temperature heat partition along the rake face maximum and average temperature history for MAL Inc User Manual for CutPro exe 156 continuous cutting and variation of the maximum temperature along the cutter rotation in the case of milling MAL Inc User Manual for CutPro exe 157 4 RUNNING A SIMULATION 4 1 RUNNING A MACHINING SIMULATION Follow these steps to define and run a simulation In the main CutPro window click New to create a new Simulation or click Open to open an existing one Enter the parameters defining the simulation See the Properties Window for more information Click OK on the Properties Window to save changes and close the window Rn Click Run to run the simulation The progress of the simulation is displayed in a DOS window below When the Simulation is done the DOS window is closed and the results are loaded automatically If you want to abort the simulation before its completion press the Stop button amp You cannot run any simulations in the DEMO version of CutPro AAS pace Milling Simulation Dynamic time domain simulation revolution 3 of i0 Figure 4 1 1 A DOS window appears when the Run button is pressed 4 2 RUNNING A TEMPERATURE SIMULATION Le Run Temp Click Run T
143. n in the following figure FRF Tope Acceleration ms N a C Displacement miM Frequency Range Hz 50 to 5000 Gain Constant i frf tope i recognized from the uff file automatically s transter function file Rigid D TestMaFRFX fi Oper Gain Y transter function file Rigid D TestMaFRFY fi Open Gain 2 transter function file Rigid T Testa RF 2 fr Open Fain TF you select a file type other than ASCII Fre the file will be converted to ASCI and saved with the New extension Figure 3 1 64 FRF Type frame in Machine amp Tool Structural Flexibility tab In the FRF Type frame you define the type of transfer function file acceleration or displacement in the x y and z directions the frequency range you wish to consider in the simulation and the gain constant of the calibration setup i e impact hammer and Ery MAL Inc User Manual for CutPro exe 92 accelerometer or displacement sensor leave the gain as 1 if you entered the sensitivity of the sensors in MalTF The existing transfer function files frf files can be downloaded by clicking on the Open button in FRF Type frame in Machine amp Tool Structural Flexibility tab frame You can also create a new transfer function file by changing the gain constant value of the current file from the Apply Gain Constant window which pops up when you click on the Gain button in the FRF Type frame in Machine
144. n this case is to find the optimal variable pitch to shift the stability lobes to the left so the process will be stable at 6000 RPM This is done in Section 9 2 4 Optimizing Variable Pitch 8 2 2 SIMULATING THE MILLING PROCESS AT 6000 RPM This section of the example illustrates how to simulate the above process at 6000RPM and an axial depth of cut of 3mm in single time domain The result of this simulation will show that the process is MAL Inc User Manual for CutPro exe 240 unstable The following steps are contained in the example file Ex02 SingleTime_6000_7mm csf Select the Advanced Milling Module choose Single Time Domain Click Next to go to the General Output tab Select the files to be saved as text files during the simulation Also the revolution and level data can be entered in the Animation Options Click Next to go to the Machine amp Tool Cutter Type tab Select Cylindrical endmill with 4 flutes at uniform pitch Click Next to go to the Machine amp Tool Cutter Properties tab Select Carbide from the cutter material drop down menu Enter the appropriate parameters as indicated at the beginning of the example Click Next to go to the Machine amp Tool Structrual Flexibility tab Select Dynamic vibrations for the Machine amp Tool Model and enter the same dynamic parameters as the previous section Click Next to go to the Workpiece Material tab Select Average cutting coefficient mode and choose Aluminum
145. nc User Manual for CutPro exe 177 WORKPIECE Figure 5 4 2 1 Definition of T and Icn 5 4 2 11 MATLAB TEMPERATURE PLOTS Please refer to the temperature plots starting in Section 1 1 1 1 for a description of the available results from MATLAB MAL Inc User Manual for CutPro exe 178 5 4 3 BORING MODULE PLOTS 5 4 3 1 CUTTING FORCES Cutting Forces Untitled csf E iol x Cutting Forces Force N pa 7 lr Msk iS x 6 468025 Options Coord s oom Reset Y 254 458946 This figure shows the cutting forces in the X Y and Z directions in three different colours Please refer to Figure 2 3 2 in Section 2 4 BORING MODULE for the definitions of the axes MAL Inc User Manual for CutPro exe 179 5 4 3 2 TANGENTIAL FORCE ioi Tangential Force iT mm cL Cs I am LL 4A Time sec E e e wS 9 53973 Options Coord s zoom Reset Y 35 588203 This result shows the force in the tangential direction MAL Inc User Manual for CutPro exe 180 5 4 3 3 RADIAL FORCE i RadiolForce Unetledcst Radial Force Force N d Time sec E ee e vi 10 29095 Options Coord s Zoom Reset 90 48224 This figure displays the force in the radial direction MAL Inc User Manual for CutPro exe 181 5 4 3 4 FEED FORCE MEE Feed Force cL co i an LL 4 Time sec E eo er vi x 9 299725 Options Co
146. nce See Figure 7 9 10 Once the identification procedure is complete a prompt save window appears Press Save The software saves the identified spindle tool holder assembly project file with the measurement files MAL Inc User Manual for CutPro exe 229 Press Next to Tool Holder Coupling 6 9 5 3 TOOL HOLDER COUPLI NG C ReceptanceCoupling File Options Help e Aa lt gt x Spindle spinde Open Save Back Next Exit p Tool Holder Geometry Tool Shank Diameter A mm hao TI Identification Inner Shank Diameter 1 mm Ba Geometry Parameters Gauge length B mm maz Holder Shank Diameterd C mm 41 04 Holder Shank Diameters C1 rr 3302 Max Tool Depth D mm 526 Taper Shank Length E mm mz Flange Length L mm aoo M Tool Dimensions g Cutter Diameter D1 is o Tool Overhang Length LI Cutter Length Le a5 o Damping A atio AT ooa o Tool Material Carbide v Impact Measurements EE Coupling Tool Holder Coupling Esport Resulting FAF Flot in MODAL Figure 6 9 25 Tool Holder Assembly Input the tool holder dimension and cutter dimensions in specified fields The cutter diameter for a 4 fluted end mill is 80 of the tool shank Recommended damping ratios for carbide tools are 0 01 0 03 Press Tool Holder Coupling to Start the Coupling Procedure Tool Holder Coupling Figure 6 9 26 Running Receptance Coupling Engine It will open a comma
147. ncy scale 10 Maternal removal rate 0 error 35 249 Surface speed m min 299 237 C Face milling Figure Cutting Conditions Milling Made Figure 3 1 93 The Cutting Conditions Milling Mode tab Slotting is selected in this figure 3 1 8 1 4 FACE MI LLI NG You have two options to define the width of cut for this mode You can either enter Entrance and Exit angle of the process or enter the value of b and b2 which are the distance of the tool center to two ends of workpiece leading the width of cut with the following equation These parameters are displayed on the side figure when you click inside of the text boxes MAL Inc User Manual for CutPro exe 120 Simulation Properties Cutting Conditions eee lt gt fl Y MANG MAOUE Back Mext Tabs Cancel OK General Machine amp Tool workpiece Cutting Conditions Temperature Spindle direction Clockwise Counterclockwise 0 Feedrate mmetlute 0 05 Spindle speed AFM 4999 998 Axial depth of cut a mr 5 Number of revolutions aol Milling Mode C Down miling C Up milling C Slotting Sampling frequency scale 10 Maternal removal ratel error Surface speed rrr 299 237 ENTER Immersion angles Entrance LN j 0 000 Exit ayl 50 956 OR ENTER gt Width of cut width 1 b mm 25 05 width 1 b mrm E Figure Cutting Conditions Milling Mode Figure 3 1 94 The Cutting Conditions Millin
148. nd window and will take a few minutes depending on the frequency selection and the speed of the computer MAL Inc User Manual for CutPro exe 226 Once the Tool Coupling is completed you can export the predicted FRF at the tool tip or plot in Modal Analysis Export Resulting FAF Plot in MODAL Figure 6 9 27 Export Resulting FRF or Plot in MODAL Press Exit to go to the main menu 6 9 5 4 LOADING EXI STI NG SPINDLE HOLDER CONNECTI ONS Press Load Existing Spindle Holder Connection Coupling of Holder and Tool Assembly to gt pindle C Identify Spindle Holder Connection Load Existing SpindlefHolder Connection Figure 6 9 28 Loading an existed project Browse for and open existing spindle holder project rsf files Couple a tool tool holder assemblies to the spindle as explained in 6 9 5 3 6 9 6 TOOL LENGTH TUNING 1 a Se i X C Tool Length Tuning Figure 6 9 29 Tool Length Tuning Tool Length tuning is based on the Tool Coupling Identification Through the Tool Coupling Identification a user selects the minimum of tool overhang length the maximum of tool overhang length and the maximum spindle speed then runs the tool length MAL Inc User Manual for CutPro exe 22 optimization engine to get the optimized tool overhang length on the certain cutting conditions for the material of Aluminum C ReceptanceCoupling Fie Options Help a a EI x Open Save Exit Too
149. ne shows y coordinates The spline could be defined by the tool manufacturer or be measured by surface measurement devices In the following you can also find information regarding the menu items in the Spline Value Editor window FILE COMMAND nai File Edit Units Help Open Cbhrl 0 Point BC ja Save Gis Point BC ct Save s Exit Ctrl g wave Length iw ave Amplitude Figure 3 1 49 File command on the Spline Value Editor window MAL Inc User Manual for CutPro exe 82 Table 3 1 9 The drop down menu of File command on Spline Value Editor window Open Open an existing Spline file Save Save the currently open Spline file under the same name Save As Save the currently open Spline file under a different name Exit Exit the Spline Editor window EDIT COMMAND w Spline Yalue Editor IOl x File Edit Units Help Slope Cut Ctrl ene Copy Chrl c Paste Ctrl V Delete Del Insert shift Ins Delete Row Shift Del Iw ave Length iw ave Amplitude Figure 3 1 50 Edit command on the Spline Value Editor window Table 3 1 10 The drop down menu of Edit command on Spline Value Editor window Cut Cut the selected range of cells Copy Copy the selected range of cells Paste Paste the clipboard contents onto the table at the selected place Delete Delete the selected range of cells Insert Row Insert an empty row at the selected place Delete Delete the selected row Row UNITS COM
150. ng Properties Average cutting coefficient Exponential chip thickness variable cutting coeticrent i Semimechanistic oel gaenen along the arial depth of cut Highorder mechanistic Tool na Orthogonal to oblique cutting PE P Sandvik materials f Bilinear force show Equation Average cutting coefficient model Tool manufacturer Cutting type Cutting condition amp Dry Lubricated Ke Mmm 27 711 Kpg Mmr 796 077 F e N mm 30 801 F o Mmr 168 829 K elm E K lM mm 222 041 Edit Equation E Jave Cancel Figure 3 1 87 Material Editor window for Fixed Materials F MAL Inc User Manual for CutPro exe 113 Import Maternals Use SHIFT click and CTAL click to select the materialla you would like to import then click OE Aluminum 4L319 Aluminum 4L356 T6 Aluminum L 075 T6 Aluminum L 075 T65 Cast Iron GGG NRC MDF Plunge Turning 0 rake angle P20 Steel Ballend mill a 0 05 in Titanium Alloy TIBAN Titanium Alloy TIBA Mitsubishi LER 160620 CCM 08359085E MA Titanium Alloy TBS Aake Angle 0 deg Titanium Alloy Tia Rake Angle 12 deg Titanium Alloy TIBA Rake Angle 15 deg Titanium 4lloy TEA Rake Angle 5 deg Select All Cancel LIE Figure 3 1 88 the Import Materials window Several materials are selected by clicking with the Ctrl key amp If you press Cancel on the Properties windo
151. ng in severe thermal stresses in addition to mechanical stresses The thermal stresses accelerate tool fatigue and failures due to fracture wear or chipping Furthermore if the temperature exceeds the crystal binding limits the tool rapidly wears due to accelerated loss of bindings between the crystals in the tool material In the temperature module developed at MAL Inc the finite difference method is used to predict steady state tool and chip temperature fields and transient temperature variation in the continuous machining and milling processes Based on the first law of thermodynamics heat balance equations are determined in partial differential equation form in Cartesian coordinates for the chip and in the Polar coordinates for the tool The finite difference method is then used for the solutions of the steady state tool and chip temperature fields In the solution procedure the heat partition between tool and chip is determined recursively In order to determine the transient temperature variation in the case of interrupted machining such as milling the chip thickness is discretized along the time Steady state chip and tool temperature fields are determined for each of these discretized machining intervals Based on thermal properties and boundary conditions time constants are determined for each discrete machining interval By knowing the steady state temperature and time constants of the discretized first order heat transfer system a
152. ng x Y and Z cutting forces Simulation Mode Opened file default csf as Untitled cst Figure 1 3 1 Simulation Properties window is displayed for the 272 Axis Milling Module by default when CutPro is started 1 3 3 MAIN WINDOW TOOLBAR BUTTONS Table 1 3 1 List of buttons on the CutPro Toolbar MAL Inc User Manual for CutPro exe 18 C New Create a new simulation Hew Open Open an existing simulation Open Save Save the current simulation Save I Properties View edit the parameters defining the a current simulation Properties Start Start the simulation Run Stop Stop the simulation Stop Wr Start Start the temperature simulation Run Tmp Stop Stop the temperature simulation Stop Tmp Plot Plot all of the simulation results or i click the drop down arrow to plot a single result Modal Load the Modal Analysis tool 7 Analysis Modal MalTF Load the MalTF transfer function measurement tool MalDAQ Load the MalDAQ data acquisition tool nS oe Milling Load the Milling Animation tool Animation Animation ur SpindlePro Load the SpindlePro tool SpindlePra uN VirtualCNC Load the VirtualCNC tool virtual NE MAL Inc User Manual for CutPro exe 19 1 3 4 MAIN WINDOW MENU COMMANDS 1 3 4 1 FILE a CutPro Untitled csf File Simulation Results Tools Window Help New Ctrl h tte Open Ctra E ad 3 a bo Save Ctrl 5 nave Pr
153. ning Figure 2 2 3 The Static Analysis mode is selected from the General tab of the Turning module This mode executes a static analysis of a turning process and is similar to the static analysis mode under the boring module See MAL Inc User Manual for CutPro exe 47 Section 2 3 1 1 Static Analysis A sample result of the static analysis mode is shown below Sample Results s Cutting Forces 200 ae Ff _ 180 m S 400 G Ti 50 o l 0 2 4 10 Time sec Figure 2 2 4 Sample Result window of Static Analysis mode PAPA ANALYTICAL STABILITY LOBES i CutPro Untitled cst File Simulation Results Tools Window Help DO gt H Mew Open Save Plot All ee Run Temp Properties Run Modal Machining UIT eT pe tn ela Process General gt x Pa Simulation Mode Hide Back Next Tabs Cancel OK a Genial Machine amp Tool Workpiece Cutting Conditions Temperature f Static analysis Predicts static cutting forces Figure 2 2 5 Analytical Stability Lobes mode is highlighted by the red box in the General tab of Turning module This mode is under development MAL Inc User Manual for CutPro exe 48 22 CUTTING COEFFICIENT IDENTIFICATION i CutPro Untitled csf Fil Simulation Results Tools Window Help D m m New Open Save Properties Run Fun Temp Flot All Modal MalTF Machining UIT Tn A te ete p Process Ganaral lt gt x f Hide
154. ns on tool Mp io Angular increments Nil 8 Tolerance E Groove width mm Og Maximum temperature history along the full fe oe cutter rotation 0 0 to 51 0 Fh a i Temperature distribution only at the exit angle cr Drilling 51 0 E Workpiece Use Matlab to display temperature distribution a Milling and contour plots Figure Position of tool and Advanced workpiece Prediction of cutting Properties forces Figure 3 1 100 Temperature Properties tab This tab was prepared for only Temperature simulation and is independent of milling and boring simulations You can find the brief description of the simulation parameters in the following Divisions along chip The temperature simulation breaks thickness Ny the chip cross section into a square grid This defines how many MAL Inc User Manual for CutPro exe Angular divisions on tool Np Angular increments Ni Tolerance Groove width mm Workpiece diameter mm Maximum temperature history along the full cutter rotation Temperature distribution only at the exit angle Use MatLab to display temperature distribution and contour plots 128 sections there are along the chip thickness thus it also determines the number of divisions along the contact length The temperature simulation breaks the cutter cross section into an angular grid This defines how many angular sections there are between the r
155. nts of Chatter Frequency and Pitch E can be entered as 1 Click Next to go to the Temperature Properties tab We are not interested in the temperature simulation for this process Click OK Click Run to run the simulation Click Results gt Plot gt Optimum Variable Pitch MAL Inc User Manual for CutPro exe E nirmi rm CE rb PMI Iie a a aie Optimum Y ariable Pitch ExO04_ Optimumpitch_6000 cs f Optimum Variable Pitch a 5 Y 25 026569 E 5 C 4 a CL cL C4 First Pitch Angle E oa eS WAS T si 70 273823 Ciptions Coord s Zoom Reset Pitches 11 624069 Angle 1 75 Angle 105 Angle 3 75 Angle 4 105 Figure 9 8 2 5 Optimum Variable Pitch result the point at 75 is selected Click on a point on the graph with a Y value larger than the desired depth of cut The point at first pitch angle 75 is selected in this case Click on Pitches to view the pitch angles of the flutes In this case the pitch angles will be 75 105 75 and 105 According to the simulation the pitch angles 75 and 105 are stable for a spindle speed of 6000RPM and a depth of cut of 7mm To check the stability of this variable pitch angle arrangement please see the next section 8 2 5 CHECKING THE STABILITY LOBES FOR THE OBTAINED VARIABLE PITCH This section illustrates how to obtain the single stability lobes for the variable pitch obtained in section 9 2 4 The f
156. o Clamp stiffness Kc N m 2 00E 05 t Flute tpe fConstant Helix Mod elasticity MPa 9 07E 11 Geometry type Tangent radius Serrated Cutter File WEN Drilling Cutter Type Cutter Properties Structural Flexibility Figure 3 1 39 Machine amp Tool Cutter Properties tab Machine amp Tool Cutter Properties tab allows you to select or define tool material and enter tool properties In this tab only the necessary parameters for the selected tool type are enabled and the parameters you define can change depending on your selection in the previous tabs 3 1 4 1 SELECT A CUTTER MATERIAL In Machine amp Tool Cutter Properties tab you can select the tool material from the list or define a new material with its specifications such as thermal conductivity density specific heat capacity and maximum allowable temperature Select a cutter material Carbide Import Delete MAL Inc User Manual for CutPro exe 78 Figure 3 1 40 Select a cutter material There are two different materials in this list defined as Fixed Material and User Defined Material You are not allowed to make any modification on Fixed Material properties but can create your own material User Defined Material and enter all specifications of the material manually Select a cutter material Figure 3 1 41 Fixed material list in Machine amp Tool Cutter Properties tab Gelect a cutter material Carbid ide High spe
157. o go to the General Output tab Check the Complete Results box if you wish to save all the results as text files Click Next to go to the Machine amp Tool Cutter Type tab Select the Cylindrical endmill with a uniform pitch of 4 flutes Click Next to go to the Machine amp Tool Cutter Properties tab Select Carbide in the Cutter Material drop down menu Input the radius as 9 525mm with a helix angle of 30 relief angle of O and rake angle of 0 Er MAL Inc User Manual for CutPro exe 238 Click Next to go to the Machine amp Tool Structural Flexibility tab Select Dynamic vibrations in the Machine amp Tool Model In this example the machine dynamics will be entered as Dynamic Parameters Therefore select Dynamic Parameters in the Machine Dynamics Mode Enter the natural frequencies damping ratios and stiffness for each direction In this example there are two dynamic modes The dynamic parameters are shown in the following table p Mode td Freq Ratio Freq Ratio O X B25 OCI 606E7 1004 001 4 3387 y 947 0 02 2 7667 0 0 Click Next to go to the Workpiece Material tab Select the Average Cutting Coefficient mode for the purpose of this example Select Aluminum AL356 T6 as the material of the workpiece from the drop down menu Click Next to go to the Workpiece Structural Flexibility tab For this example the workpiece is assumed to be rigid Hence select Rigid in the Workpiece Material Click Next
158. ocess stability under flexible tool workpiece conditions Stability Lobes Most accurate predictions of chatter free axial and radial depth of cut and spindle speeds 2D spindle speed axial depth of cut and 3D spindle speed axial depth of cut width of cut Chatter Stability diagrams Simulates time domain stability lobes Design and analysis of inserted indexable cutters Design and analysis of variable geometry _ helical endmills Design of variable pitch cutters tuned to a specific material and spindle for chatter suppression Design and analysis of serrated cutters Automated identification of cutting constants from milling tests User specified material data entry Simulates stability lobes and forces for a batch of conditions with multiple immersions Animates cutting processes in discrete domain with vibrations of tool and workpiece 1 2 1 2 PLUNG MILLING MODULE The Plunge Milling Module has the following features Simulates plunge milling plunge milling with a pilot hole and side plunge milling cutting conditions Analysis of Symmetric and asymmetric tool types with user defined inserts Makes the following predictions and analysis Cutting forces in three directions and surface error under rigid tool workpiece clamping conditions Chatter vibration dynamic milling forces tool and workpiece vibrations surface finish roughness spindle power spindle bending moment chip thickness and process s
159. odule This mode enables you to look for the optimum variable pitch angles in order to make a particular cutting condition stable This is useful when a desired cutting condition is unstable with a uniform pitch The result of this mode shows sets of optimum pitch angles and their corresponding maximum depths of cuts allowed for a stable process in the cutting conditions specified The sample result window of Optimize Variable Pitch mode is shown below MAL Inc User Manual for CutPro exe 4 x Optimum Variable Pitch Ey E 40 E i i 3 H F i a 1 I r n gt L H T z Ei r F L F 2 I M j ry b ic pt Ci a oy ae 0 20 di Bo ai boo First Pitch Angle Figure 2 1 14 Sample Result window for Optimize Variable Pitch 2 1 1 6 CUTTING COEFFICIENT IDENTIFICATION 4 CutPro Untitled csf File Simulation Results Tools Window Help New Open Save Properties Run Run Temp Plot All Modal MalTF Genera lt gt f y Simulation Mode Back Nexk Tabs Cancel OK L ay Machining Process General Machine amp Tool workpiece Cutting Conditions Temperature Simulates cutting forces tool vibrations surface finish spindle C Single time domain power and spindle bending moment in a single time damain a c Stability lobes in time Use this mode to simulate stability lobes within a narrow speed range Turnin domain for a complicated cutter Otherwise se
160. of flutes rilling c Cutting coefficient Automatically identifies the cutting coefficients based on files identification defining amp Y and lt cutting forces Simulation Mode Figure 2 1 10 The Multiple Analytical Stability Lobes mode is selected in General tab of the 2 Axis Milling module MAL Inc User Manual for CutPro exe 39 This mode simulates the stability lobes in frequency domain for a milling process with several different steps For example the process represented by the following diagram involves a half immersion down milling a full immersion milling slotting and a half immersion up milling Figure Multiple analytical stability lobes Figure 2 1 11 A sample multiple steps milling process Begin with a half immersion down milling then slotting and a half immersion up milling In order to obtain a stable process the cutting conditions must produce stable results for all the steps involved in the operation The sample result window of the multiple analytical stability lobes mode is given by the following figure Sample Result j x Stability Lobes Multiple Anal Titia mm wy Bee I ae 3005 E if PF fo oO 0 bi 1205 ky z wea w La dii ee aa i Lstaiitn PEENE ee MAPPER SPPrrrrrrrrer Sverre er MAERA i S000 10000 15000 28000 34000 adii Spindle Speed rpm Figure 2 1 12 Sample Result window of Single Analytical Stability Lobes mode MAL
161. of flutes Cutting coefficient Automatically identifies the cutting coefficients based on files identification defining Y and cutting forces Simulation Mode Output Figure 2 1 6 The Stability Lobes in Time Domain mode is selected in General tab of the 2132 Axis Milling module This simulation mode simulates the stability lobes in the time domain to determine stability border for the particular milling process Stability lobes Chatter stability is expressed by the stability lobes figure which defines the boundary that separates stable and unstable machining in the form of axial depth of cut limit versus spindle speed for a fixed radial width of cut and workpiece tool combination The region under the stability lobes is stable and the region above the stability lobes is unstable The sample result MAL Inc User Manual for CutPro exe 36 window for the Stability lobes in time domain mode is given by the following figure xj Stability Lobes p E Oo UNSTABLE rl Pee F a ad 14 M 1 fl yo y i I i MW NS STABLE ae e ct tne i S000 00a io p d 25000 3000 Spindle Speed rpm Figure 2 1 7 Sample Result window of Stability Lobes in Time Domain mode Basically this mode simulates the process in the time domain with small increments within the spindle speed and depth of cut ranges specified by you See Section 3 1 10 Cutting Conditions Other Parameters and decides whether
162. ol Structural Flexibility tab You can download existing cmp files by clicking on the Open button in Figure 3 1 66 If you click on the New button in Figure 3 1 66 the New Residue File window in which you can create a new cmp file from an existing transfer function file frf file pops up f i New Residue File Untitled O x Fie Modes Results Options Tools sia p 0 i 4 Rie g Bo Hu Chane Orsi M i arena Oeste O 1 Pew fl O adi eed Pen fh haa 2 CO bean LI kd maa lal E ee FRF Files Measurement Point 1 Location z mm Acceleration g l C Displacement Frequency Range Hz j Ti to 5000 OF j Clear Defaults Gain Constant i Cancel 2 3 4 wt bw Hos js G H M Options Modes Cursor zoom Reset Real Imaginary Magnitude Figure 3 1 67 New Residue File window You can exclude the dynamic effects of the direction you want on the structure by checking the box next to the Rigid option in Figure 3 1 66 Please see Section 10 2 Appendix A2 Modal residue data files for more information 3 1 5 2 3 DYNAMIC PARAMETERS MAL Inc User Manual for CutPro exe 94 If you know the dynamic parameters of the system such as natural frequencies damping ratios and stiffness values of the modes you can simply enter them by choosing the Dynamic Parameters option When you select this option the following frame shows up Dynamic Parameters Direction Ef Mo
163. ollowing steps are contained in the example file Ex06_SingleAnalytical_Var csf MAL Inc User Manual for CutPro exe 245 Select the Advanced Milling Module Select Single Analytical Stability Lobes mode The rest of the steps are identical to section 9 2 4 with the exception that on the Machine amp Tool Cutter Type tab instead of selecting Uniform pitch select Non uniform pitch Enter 75 for Pitch 1 105 for Pitch 2 75 for Pitch 3 and 105 for Pitch 4 Run the simulation Click Results gt Plot gt Stability Lobes Anal Var Pitch Stability Lobes Anal Yar Pitch Ex05_SingleAnalytical_ ar csf Ioj x Stability Lobes Anal Yar Pitch o0 E 5 C2 Lj oo CL L O 10000 20000 S0000 40000 Spindle Speed rpm E Coe eo a u s i 6751 968099 Options Coord s oom Reset 103 994513 Figure 9 8 2 6 Unsorted Stability Lobes with the variable pitch tool The unsorted stability lobes for this process are displayed Note that the stability lobes for variable pitch are not sorted To ensure a condition is stable make sure the corresponding point is beneath all curves on the stability lobes According to the stability lobes the process is stable at Spindle Speed 6000RPM and Depth of Cut 7mm You can run the process at 6000RPM with the 75 and 105 pitch angles on the machine MAL Inc User Manual for CutPro exe 246 8 3 EXAMPLE B OBTAINING STABILITY LOBES I
164. om In Increase magnification of the figure You can also zoom in by clicking the figure with the left mouse button Zoom Decrease magnification of the figure You can also Out zoom out by clicking the figure with the right mouse button Save Save any change you have made editing the insert type and close the Insert Editor window Cancel Close the Insert Editor without saving any changes If you click on the New button in the Edit Insert Cutter Types window the New Insert window pops up in which you can select the shape of the new insert type MAL Inc User Manual for CutPro exe 89 Please select the shape of the new insert type Convex tiangular ok Figure 3 1 59 New Insert window Pakha MACHINE amp TOOL STRUCTURAL FLEXIBILITY TAB 4 CutPro Untitled csf i fy 13 rr d Properties Run Run Temp Plot All Modal MalTF M Machining EEL a L Process agachine amp Tool gt x y Hide Al E Structural FIGKIDUIY pack Mext Tabs Cancel OK File Simulation Results Tools Window Help DO H Mew Open Save General Machine amp Tool Work piece Cutting Conditions Temperature Machine amp Tool Model Rigid f Dynamic vibrations C Static deflections Machine Dynamics Mode Dynamic Parameters Direction ya Y Mode no Mat freg Hz 500 700 500 C Modal residue data files Damping ratio Joos joo 0 05 stittness N m 1 006 07 1 00 07 1 006 07
165. ometry of the cutting tool High order mechanistic Based on an average cutting coefticient model but the r r r Exponential chip thickness THe cutting coefficients have an exponential relationship with r 3 d cutting coeffc coefficients are a function of chip thickness r Sad meae The cutting coefficients hawe an exponential relationship with some power of chip thickness Figure 3 1 79 Cutting Coefficient Model list in Workpiece Material tab The following cutting coefficient models are available in CutPro Average cutting coefficient Variable cutting coefficient along the axial depth of cut Orthogonal to oblique cutting transformation Bi linear force Exponential chip thickness Semi mechanistic High order mechanistic Sandvik materials Cutting Coefficient Identification Procedure in CUTPRO MAL Inc March 13 2006 Vancouver B C CUTPRO can automatically identify cutting coefficients with its associated option in the general tab of the milling module You need to conduct a series of milling tests and collect the data in ASCII or MALDAQ mdq formats If you use the log data option in MALDAQ you will need to load the part of the data you are interested in first and then save the data as a MALDQ mdq binary file It is convenient to name the files as S5000_N2_c0050_a5 Spindle speed 5000 rpm Number of teeth 2 Feed per tooth 0 0050 mm Axial depth of cut a 5 mm MAL Inc User Manual for Cut
166. on flank face HIGHER ORDER MECHANISTIC The higher order mechanistic model is based on the average cutting coefficient model but the coefficients change based on the polynomial order of chip thickness High order mechanistic model Rel Kie Ne fe Kiol Reef o ooo Kad Edit Equation Order f ero E First C Second Third Figure 3 1 86 Higher order mechanistic model frame in Material Editor window The following parameters define the high order mechanistic model Table 3 1 267 Parameters for Higher order mechanistic model Order Zero first second or third order F MAL Inc User Manual for CutPro exe Kte Kre Kae Ktc Krc Kac Tangential edge force coefficient N mm Radial edge force coefficient N mm Axial edge force coefficient N mm Tangential shearing coefficient N mm Radial shearing coefficient N mm Axial shearing coefficient N mm 112 After you define the parameters click on Save button to save the values you entered or click on Cancel button to cancel and close Material Editor window without saving the parameters When you click on View button in order to see the specifications of the workpiece material the following Material Editor window shows up Material Editor i f File Properties Material name Aluminum AL7075 T Description Composition 5 54 Zn 2 5 Mog 1 5 Cu 03 Cr Was 0 5 Fe Max 0 4 5i Max 0 3 Mn Cutting Coefficient Model Cutti
167. on model Equations 247 Orthogonal to oblique cutting transformation model Material editor 111 Output tab 145 Pitch type 72 73 R RDOF 210 RECEPTANCE COUPLING 207 213 216 217 Results 155 Rotational Degrees of Freedom 210 Running a simulation 154 Run out 73 81 133 134 MAL Inc User Manual for CutPro exe Run out deviations 73 Run out file editor 74 134 S Saving modal parameters 203 Selecting modes 199 Semi mechanistic 99 251 Semi mechanistic model Equations 251 Semi mechanistic model Material editor 114 11 43 132 Single Analytical Stability Lobes 126 SPINDLEPRO 15 16 Starting a new simulation 17 System Requirements 9 269 T Temperature 131 132 159 160 171 Temperature Prediction 152 TEMPERATURE PREDICTION 152 TOOL TEMPERATURE CONTOUR ON XY PLANE 161 TOOL TEMPERATURE DISTRIBUTION 160 U unsorted stability lobes 231 UP MILLING 120 y Variable cutting coefficient model Material editor 110 MAL Inc User Manual for CutPro exe
168. on the tool when you change them on the next tabs The following buttons appear in the figure window Table 3 1 2 Buttons on Tool Geometry window Zoom In Increase magnification of the figure the scale of the figure to the endmill s actual dimensions is displayed in the lower right corner of the figure You can also zoom in by clicking the figure with the left mouse button Zoom Decrease magnification of the figure the scale of Out the figure to the endmill s actual dimensions is MAL Inc User Manual for CutPro exe 69 displayed in the lower right corner of the figure You can also zoom out by clicking the figure with the right mouse button Print Bring up a print dialog which allows you to print the figure at its current magnification Close Close the figure window Cylindrical Cutter Geometry 5 x 9 55 Scale 220 Use the lett mouse button bo 200m in right button to 200m out and holding down the CTAL key click and drag to move the zoom centre Zoom Out Frint Close Figure 3 1 23 Cylindrical endmill cutter geometry MAL Inc User Manual for CutPro exe Ar Ball end Cutter Geometry 9 53 Spade 220 Use the left mouse button to zoom in right button to 200m out and holding down the CTAL key click and drag to move the 200m centre oom Out Reset Print Close Figure 3 1 24 Ball endmill cutter geometry Ar General Tool Geometry scale 429 Use the left mouse but
169. operties Fun Run Temp Flot All Modal MalTF SAVE AS 1 Properties i Close Ctrl gt ahon idode Bak nei x y Cancel OK Tabs Ctrl g General Machine amp Tool Work piece Cutting Conditions Temperature m Figure 1 3 2 File menu on CutPro Table 1 3 2 The drop down menu of File command New Create a new simulation Open Open an existing simulation Save Save the current simulation Save As Save the current simulation under a different name Close Close the current simulation Recent Files Select recent files to open Exit Exit CutPro amp When you Save a CutPro simulation all of the currently loaded Results are saved as well as the Simulation Properties amp You can neither Save nor Print in the DEMO version of CutPro 1 3 4 2 SIMULATION if CutPro File Simulation Results Tools Window Help i Run Ctrl F m S Stop E 7 ee Me Run Temp Flat All Modal MalTF Run Temperature Mat Stop Temperature ee Pr Properties gt Hide x yi WIV Back Next Tabs Cancel OK General Machine amp Tool workpiece Cutting Conditions Temperature Figure 1 3 3 Simulation menu on CutPro MAL Inc User Manual for CutPro exe 20 Table 1 3 3 The drop down menu of Simulation command Run Run the simulation Stop Abort the simulation Run Temperature Run the temperature simulation Stop Temperature Abort the temperature simulation Properties V
170. or Before you measure the transfer function of the system take into consideration for the following instructions If the machine cutter and workpiece are flexible measure the transfer functions for both If the depth of cut is not large you can take the transfer function measurement only from tool tip and workpiece at very close location of the surface If you are measuring the transfer function for multiple points along the depth of cut take the first point at tool tip for Machine Dynamics or very close to the workpiece surface for Workpiece Dynamics MACHINE CUTTER STRUCTURE ee Level 1 HEH Level 2 Ere Level 3 Baad TOOL Cia H Level 3 Level 2 Ty ie Sia Cod rA TT Level 1 meres Tt er Repeat the tests in X and Y directions separately F MAL Inc User Manual for CutPro exe 210 Modal analysis software is used to identify the dynamic parameters of the structure Pose ur ane Pile Pica esd hacer Booker TP iste ee ee ee ee a a Ho Fourler Analyzer Transfer functions are meas ured at several points along the cutter using an impact Els hammer accelerometers or ie ale pr ad lc ie displacement sensor id appeal dynamic parameters to and a Founer analyzer aE RART may originate from the cutter spindle tool holder or workpiece Figure 6 8 1 Flowchart describing the modal analysis process 6 9 RECEPTANCE COUPLING
171. or CutPro exe 29 1 4 ACTIVATING MODULES In order to use the FULL version of CutPro you must have a CutPro hardlock security key and a valid password for each module you wish to use You will be prompted to enter these passwords the first time you run CutPro To obtain your passwords please contact MAL Inc To enter your passwords select License Information from the Help menu in the main CutPro window Once you have entered the passwords for the modules you are authorized to use press the Verify button Finally press Done to close the window and you can continue using CutPro License Information Serial 4400 Please check each module below for which pou have a valid password Enter the password for each then click Verity J Milling Simulation SPCD 1 234 Turming Simulation Boring Simulation Grilling Simulation Temperature Simulation WM Modal Analysis 4321 DLBA MalTF MalDAg SpindlePra Simplified Milling Simulation Virtual CHC TTR Verity Done Figure 1 4 1 License Information window where the passwords of the modules are entered MAL Inc User Manual for CutPro exe 30 2 MODULES 2 1 MILLING MODULE Figure 2 1 1 Axes definition of a milling process Note that the X direction is the feed direction 2 1 1 2 2 AXIS MILLING MODULE CutPro Untitled cst File Simulation Results Tools Window Help ie E w New Open Save Properties Run Machining Process
172. orce Resultant Force in the 4 Plane Cutting Force Tangential Cutting Force Chip Thickness Tool Vibration Tool Deflection Workpiece Vibrations Upmilling Surface Finish Bownmiling Surface Finish Stability Lobes analytical Stability Lobes onal var Pitch Stability Lobes Mime Borrain Spindle Power Spindle Torque Spindle Bending Moment Optimum Variable Pitch Figure 1 3 5 Results menu in CutPro Plot window MAL Inc User Manual for CutPro exe 22 a CutPro Untitled cst Fie Simulation Results Tools Window Help Export Resultis D l Select data to export new Q Plot al Modal MalTF MaDAQ Sp Forces He YZ Tangential and 7 Directions Machining Process File name PT Save Cancel File Browse Save ini E Program d fe HE MalSound SpindlePra Temperature VirtualChic Drilling File name z Save as type Manag File rndt Cancel CutPro Simulation Files bt Data Files dat MalD AQ File rdt ie elw ork F MalDAG File rodq Figure 1 3 6 Results menu of CutPro Export Results window F MAL Inc User Manual for CutPro exe 23 o File Edit id 7 ie fl Mew Open Summary of simulation conditions Simulation File name Untitled csf Generat Time date April 13 2005 at 14 54 File Simulation Results Machining Process Cutting mode Milling Simula Simulation mode
173. ord s Zoom Reset Y 3504037 This figure shows the force in the feed direction MAL Inc User Manual for CutPro exe 182 5 4 3 5 AREA OF CUT io xI Area of Cut N x E ro a lt E 4 Time sec D ue EOS ps Options Coord s oom Reset MAL Inc User Manual for CutPro exe 183 5 4 3 6 SPINDLE POWER 15 x spindle Power 0 5 0 4 gt 03 p a z 2 0 2 i 0 1 0 0 D 2 4 B 3 10 Time sec ee oe ee pws xi 8 946399 Options Coord s 200m Reset Y 0 127512 This plot shows the Spindle Power MAL Inc User Manual for CutPro exe 184 5 4 3 7 SPINDLE TORQUE io x Spindle Torque DI i z cL y p oo L A Time sec E a ee e s si 10 849324 Options Coord s oom Reset Y 0 032894 This plot shows the Spindle Torque MAL Inc User Manual for CutPro exe 185 5 4 3 8 BORING BAR RADIAL DEFLECTION Boring Bar Radial Deflection Untitled csf 5 x Boring Bar Radial Deflection 0 20 40 60 o0 0 000 E a ee vi s 100 131539 Options Coord s Zoom Reset Y 0 000806 The radial deflection of the boring bar is displayed in this plot X is the length along the boring bar and Y is the radial deflection MAL Inc User Manual for CutPro exe 186 5 4 3 9 ANALYTICAL STABILITY LOBES A Stability Lobes Analytical Untitled csf stability Lobes Analytical mm ae ae ell n Cj p aw
174. orkpiece Cutting Conditions Temperature Simulates cutting forces tool vibrations surface finish spindle Single time domain power and spindle bending moment in a single time domain r Stability lobes in time Use this mode to simulate stability lobes within 4 narrow speed range domain for a complicated cutter Otherwise see below ie Single analytical A fast analytical stability lobes prediction solved in a frequency stability lobes domain co Multiple analytical Generates stability lobes with axial and radial depths of cut and stability lobes spindle speed r Optimize variable Automatically calculates pitch distribution at a specific spindle pitch speed for a given number of flutes Drilling r Cutting coefficient Automatically identifies the cutting coefficients based on files identification defining Y and cutting forces Simulation Mode Figure 2 1 8 The Single Analytical Stability Lobes mode is selected in General tab of the 212 Axis Milling module This mode simulates the Stability lobes in frequency domain In this mode the process is modeled by using the linear stability theory Nonlinearities such as the tool jumping out of cut multiple regeneration process damping run out and nonlinear cutting coefficients are neglected in linear stability analysis which makes it a very quick simulation It generates the stability lobes by indicating the axial depth of cut and spindle speeds for a fixed ra
175. p Total gain constant for the transfer function is MAL Inc User Manual for CutPro exe 201 TrFunc a F Volt Volt hammer sensitivity TrFunc Volt accelerometer sensitivity mV 0 22 mae TrFunc ct Nyc 0 417188 Volt 5 17 Y 9 102 8 g m s 6 3 6 FREQUENCY RANGE This defines the range of frequencies in which the modal analysis is done Do not give zero for the fist value Modal Analysis package displace the transfer function as displacement force If you measured the acceleration and give the first range value as zero the transfer function magnitude value will be infinite at zero frequency It will also have very large amplitude value for low frequencies Give an initial value for the first range to eliminate this error 2 6 3 7 BUTTONS Clear Restores the values of all fields in the Open FRF Defaults Files window to the defaults Cancel Closes the Open FRF Files window without saving any changes OK Saves any changes which have been made and closes the Open FRF Files window You can try the example files provided TestFRFX11 frf and TESTFRFX12 frf which contain actual test measurements Modal uses only one of the files for curve fitting the file that contains the highest flexibility i e at the tool tip and the other files are handled automatically by Modal Analysis program amp In the CutPro DEMO version of Modal Analysis you can only open the ex
176. pe CutPro Simulation Files csf Cancel WE Figure 5 1 1 Save Document window 5 2 EXPORTING RESULTS Select Export from the Results menu then specify the ASCII text file txt to which you want to export it The exportable results change after every simulation You can either type the name of a text file in the box provided or find an existing file to write over by pressing the browse button eS Export Results Select data to export eee File Name COCO 24 Save The output file is in ASCII format The format description is in the following section 6 3 RESULTS FORMATS 5 3 RESULTS FORMATS eL FORCES IN X Y Z AND TANGENTIAL DIRECTIONS The first column is time sec The second column is cutter rotation angle deg MAL Inc User Manual for CutPro exe The third column is Fx force N The fourth column is Fy force N The fifth column is Fz force N The sixth column is Ft tangential force N Example 0 0000E 00 0 0000E 00 3 4969E 01 3 6653E 01 2 4108E 00 3 5117E 01 1 2500E 04 4 5000E 00 3 5070E 01 3 7246E 01 2 5750E 00 3 5706E 01 2 5000E 04 9 0000E 00 6 7297E 01 8 1075E 01 6 1615E 00 7 5037E 01 Se Ae TOOL VIBRATIONS IN X AND Y DIRECTIONS The first column is time sec The second column is vibration in X direction mm The third column is vibration in Y direction mm Example 0 0000E 00 6 0987E 04 2 4275E 03 1 2500E 04 1 4336E 03 6 8409E 03 2 5000E 04 1 4878E 03 1 0149E
177. pen Save Properties Run Run Machining Process Turning Figure 2 2 1 Turning module MAL Inc User Manual for CutPro exe 46 4 CutPro Untitled cst File Simulation Results Tools Window Help De H kA VEE E New Open Save Properties Run Run Temp Plot All Modal Machining tet eu a i Process Generar lt gt x s Hide Sumivetion Mode Back Next Tabs Cancel Ok General Machine amp Taol workpiece Cutting Conditions Temperature f Static analysis Predicts static cutting forces Analytical stability Use this mode to simulate stability lobes within a narrow speed lobes range Cutting coefficient Automatically identities the cutting coefficients based on files identification defining Tagential Radial and Feed cutting forces r2 Drilling Simulation Mode Figure 2 2 2 The General tab of the Turning module PAPA STATIC ANALYSIS W CutPro Untitled cst Fie Simulation Results Tools Window Help 4 a Mew Open Save Properties Run Run Temp Plot all Modal MalTl Turning Simulation Properties l General lt gt fied Y Simulation iviode Machining Process Back Merck Tabs Cancel Ck General Machine amp Tool Workpiece Cutting Conditions Temperature fe Static analysis Predicts static cutting forces Analytical stability Use this mode to simulate stability lobes within a narrow speed Ne rs lobes range Tur
178. r Type Back Next fide v Tabs Cancel OK General Machine amp Tool Work piece Cutting Conditions Temperature Flutes Humber of flutes f Cylindrical end Figure Tool Ball end Uniform pitch flutes are spaced egually C Nor uniform pitch Pitch t 7 is zog Uniform helis all flutes have the same helis angle E Nor uniform helis gt l gt Helix 1 ie 0 Use run out deviations File Cutter Type Structural Flexibility Figure 3 1 21 Machine amp Tool Cutter Type tab i General endmill E Indexable cutter Drilling Ery MAL Inc User Manual for CutPro exe 68 This tab allows you to choose the cutter type and to define number of flutes the type of pitch and helix angles and run out deviations Different options are available for different simulation modes in this tab In Machine amp Tool Tool Type tab the following options are enabled 3 1 3 1 CUTTER TYPE f Cylindrical end Ballend C General endmill A C Indesable cutter Figure 3 1 22 Cutter Type in Machine amp Tool Cutter Type tab You have four options for the tool type namely cylindrical ball and general endmills and indexable cutter on the list given in Figure 3 1 22 When you choose the tool type a figure will show general look of the selected tool on the right hand side of the Simulation Properties The figure will also help you visualize the parameters
179. r multiple modes in each direction and specify any rigid directions 2 3 2 3 ANALYTICAL STABILITY LOBES This mode simulates the analytical stability lobes in the frequency domain by using 2D chatter stability theory for a boring process The boring head analytical stability lobes mode of the boring module and the single analytical stability lobes mode of the 212 axis milling module use the same engine See Section 2 1 1 3 Single Analytical Stability Lobes The sample results window of the boring head analytical stability lobes mode is the same as the sample results window of the single analytical stability lobes mode of the 2 axis milling module CutPro Untitled csf Fie Simulation Results Tools Window Help a H D A ey ae oe a 4 Mew Open Save Properties Run Temp Modal Mam m Machining Process General gt gt Hide v Simulation Mode Next Tabs Cancel OK Work piece Cutting Conditions Static Analysis Simulates cutting forces spindle power and torque when tool and workpiece can be assumed to be rigid C Dynamic simulation Simulates cutting forces tool vibrations spindle power and torque In a time damain a Snalptical stability A Fast analytical stability lobes prediction solved in a frequency lobes domain Simulation Mode O utpat Figure 2 3 9 The Analytical stability lobes mode is selected in the General tab of the Multi I nsert Boring module MAL Inc User Manual for CutPro exe
180. rameters Figure 3 1 97 Cutting Conditions Other Parameters tab for Multiple Analytical Stability Lobes simulation mode For this simulation mode you will define simulation steps on this tab You can see the brief definition of these parameters which have to be defined in the following Y start offset Defines the starting position of the tool as Yst measured from the center of the cutter to MAL Inc User Manual for CutPro exe 124 the center of the workpiece A negative value positions the tool above the middle of the workpiece a positive value positions the tool below the middle of the workpiece Start width h Alternatively defines the starting position of the tool If positive the value is the distance from bottom of the workpiece to the top edge of the cutter if negative the value is the distance from the top of the workpiece to the bottom edge of the cutter Workpiece The width of the workpiece Changing this width w value may result in automatic changes in the other parameters Y end offset Defines the ending position of the tool as Yen Y start offset above End width h2 Alternatively defines the ending position of the tool as Start width above Step Defines the vertical distance between steps in the simulation The total number of steps is determined by Step as well as the difference between Y start offset and Y end offset by dividing difference Step amp All parameters are subject to ce
181. ring module MAL Inc User Manual for CutPro exe 53 This mode is similar to the static analysis mode described in section 2 3 1 1 Static Analysis but instead of having a boring bar with only one insert you can define multiple inserts on a symmetric or an asymmetric tool 2 3 2 2 DYNAMIC SIMULATION Sample Result Tool Tip Vibration dud I i on 1 haan I dik y O04 Ee D Ii li i Time sec W CutPro Untitled csf Fie Simulation Results Tools Window Help y Lo 3 New Open Save Properties Run Run Temp Modal Malt M Machining Process General Simulation Mode gt fice e vy soit i Next Tabs Cancel OK end General Machine amp Tool workpiece Cutting Conditions Simulates cutting forces spindle power and torque when tool and f Static Analysis f Dynamic simulation m Analytical stability lobes workpiece can be assumed to be rigid Simulates cutting forces tool vibrations spindle power and torque in a time domain fast analytical stability lobes prediction solved in a frequency domain Figure 2 3 8 The Dynamic Simulation mode is selected in General tab of the Multi Insert Boring module MAL Inc User Manual for CutPro exe 54 This mode is similar to the static analysis for multi insert boring but instead of assuming that the tool is rigid the dynamic parameters of the tool are entered by the user Of course the user can enter parameters fo
182. rol Panel Double click on the icon labeled Add Remove Programs Select CutPro from the list and press Add Remove This will remove the software from the system 1 2 CUTPRO MODULES MILLING The milling module is highly accurate and the most comprehensive simulation software for optimum planning and trouble shooting of milling processes The milling module has two sub modules with the following features i Reena 1 2 1 1 212 AXIS MILLING MODULE The 212 Axis Milling Module has the following features Simulates regular endmills variable pitch cutters ball endmills indexable cutters serrated cutters and endmills with any user defined geometry Has built in properties of a variety of materials such as Waspeloy Inconel Aluminum and Titanium alloys Steel standard Sandvik and Kienzle materials Accepts dynamic parameters of the machine tool and workpiece manually by you or in a variety of formats i e frf uff HP sdf cmp files created in CutPro or other commercial modal analysis software packages Makes the following predictions and analysis Simulates cutting forces in three directions and Surface error under rigid tool workpiece clamping conditions Simulates chatter _ vibration dynamic milling forces tool and workpiece vibrations in the feed and normal directions x and y surface _ finish roughness spindle power spindle bending moment MAL Inc User Manual for CutPro exe 11 chip thickness and pr
183. rom the drop down menu Lee THE MAIN WINDOW When you first open CutPro the main window appears This window consists of a toolbar as well as a series of menus The Properties Window is automatically displayed CutPro Untitled csf Sel File Simulation Results Tools Window Help Pp D oni New Open Save Properties Run Run Temp Plot All Modal MalTF MalDAQ SpindlePro VirtualCNC Animation Machining Sample Result Process General lt gt a x of Simulation Mode bak Next Tabs Cancel OK General Machine amp Tool Workpiece Cutting Conditions Temperature G Single analytical fast analytical stability lobes prediction solved in a frequency istability lobes domain Depth of Cut mm j Milling process Simulates cutting forces tool vibrations surface finish spindle eee Meee ee simulation power and spindle bending moment in a single time domain 0 5000 10000 15000 20000 25000 30000 Spindle Speed rpm Multiple analytical Generates stability lobes with axial and radial depths of cut and stability lobes spindle speed Bori F a oneg e Stability lobes in time Use this mode to simulate stability lobes within a narrow speed range domain for a complicated cutter C Optimize variable Automatically calculates pitch distribution at a specific spindle pitch speed for a given number of flutes ge Cutting coefficient Automatically identifies the cutting coefficients based on files identification defini
184. rrin ninen EE EEE 12 tad MODAL ANALY Oeren AEE 13 E2 MAET P rone E E EEEE O E 13 EZO MALEDA O a A E E 14 kAd OF LINDLEPR O srrinirise eanne EEE 15 BZ VIRTUALO N orana eeni E E E ETE EE 16 1 3 OVERVIEW OF CUUPRO wissisitacecesseaserctivaderetnsrenesees 17 PoE STARTING COOTER Ox oerrinne na ROE REENE 17 Lo THE MAIN WINDOW sxineieecavcinonstrescumiasenpocnsamennecasemeneas 17 1 3 3 MAIN WINDOW TOOLBAR BUTTONS ccccceeeeeeee eens 17 1 3 4 MAIN WINDOW MENU COMMANDS cccceeeeee eee e eee 19 1 4 ACTIVATING MODULES ccccccccccseecennneeeeeeeeeeeeeennneees 29 2 MODULES rerne roe yer cre 30 2 1 MICLELING MODULE icrisssnrintarnrnin aunir 30 ALL ZA AA SO MILLING MODULE aerer N T 30 2 4 2 PLUNGE MIELING MODULE c c sevcbasensmuiseedeunvasiabesoonan 43 2 2 TURNI NG MODULE sssssnsnnnnnnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 45 ALe ATAC ANAC Ol gt a E 46 Zee ANALYTICAL STABILITY COBDES diseransce ic annentonrsanin inneas 47 2 2 3 CUTTING COEFFICIENT IDENTIFICATION acceca 48 2 3 BORING MODULE ccccccccccccceccceeeeeeeeeeeeeeeeeeeeeeeennonaes 49 2 324 ANGLE INSER F MODUL E rraian 50 2 3 2 MULTI INSERTS MODULE inc cssmnstansens sntamecniacessaminedeewns 52 3 SIMULATION PROPERTIES WINDOW S TABS AND DEFINITIONS sireni ennn EAEE 55 3 1 21 2 AXIS MILLING MODULE sssssssnnnnnnnsnnnnnnnnnnnnnnnnnnn 55 3 1 1 GENERAL SIMULATION MODE TAB cece cece 55 3d GENERAL OUTPUT TAB rrr nna 56 3 1 3 MACHINE amp TOOL CUTTER
185. rtain value restrictions If you enter an invalid number you will be asked to change it amp Click on the Show Hide Simulation button to see a graphical representation of the simulation parameters MAL Inc User Manual for CutPro exe 125 3 1 9 2 OPTIMIZE VARIABLE PITCH CutPro Untitled csf File Simulation Results Tools Window Help D ae H a New Open Save Properties Run Lee Run Temp Plot All 7 lin Sp Modal MalTF MaA SpindleProa Animation Machining ELNE Sin toga Process Cutting Conditions gt el E Giner Parameters Back Next Tabs Cancel OK Ses es General Machine amp Tool Workpiece is sre zm Milling Pitch Distribution Type Parameters for Optimize Variable Pitch f Two different angles Starting angle T Linear angles Chatter freq incr Hz 1 C Sinusoidal angles Meelis Tet 1 Milling Advanced Prediction of __ cutting Milling Mode Other Parameters Figure 3 1 98 Cutting Conditions Other Parameters tab for Optimize Variable Pitch simulation mode For this simulation mode you will define Pitch Distribution Type and Parameters for Optimize Variable Pitch You can see the brief definition of these parameters in the following Two different Only two pitch values are used and are angles alternated around the cutter e g 30 60 30 60 etc Linear angles Variation in the pitches is assumed to
186. s This plot shows the cutting force in the tangential direction MAL Inc User Manual for CutPro exe 169 5 4 2 3 RADIAL FORCE speadialrorce unttiedesf OOOO lO x Radial Force ci i m m LL A Time sec fe BAS aS w 4 789457 Options Coord s Zoom Reset Y 98103349 This plot shows the cutting force in the radial direction MAL Inc User Manual for CutPro exe 170 5 4 2 4 FEED FORCE Feed Force Untitled csf a ol x Feed Force Force N 4 Time sec wif EOS pws 11 024203 Options Coord s oom Reset Y 55 601004 This plot shows the cutting force in the feed direction MAL Inc User Manual for CutPro exe 171 5 4 2 5 AREA OF CUT gt Area of Cut Untithed csf E O x Area of Cut N z E yn 4 Time sec wil BG pes Options Coord s zoom Reset This plot shows the area of cut MAL Inc User Manual for CutPro exe 172 5 4 2 6 SPINDLE POWER ioja Spindle Power aT o a A Time sec ae fey EOS WS 9 921637 Options Coord s Zoom Reset Y 0074651 This plot shows the spindle power MAL Inc User Manual for CutPro exe 173 5 4 2 7 SPINDLE TORQUE Spindle Torque Untitled csf f l 5 x spindle Torque Di i z d Eg a m _ 4 Time sec ee oe EOS ps x 10 61893 Options Coord s foom Reset Y 3 596196 This plot shows the Spin
187. s a function of feed rate c and immersion angle The chip thickness expression used in the Approximation option is given by the following equation h csing 1 If you prefer using the Approximation option for the chip model you will have an error which is negligible in the simulation results 3 1 5 2 MACHI NE DYNAMI CS MODE There are three different machine dynamics modes namely Measured t f file Modal residue data files and Dynamic parameters available in this tab MAL Inc User Manual for CutPro exe 91 Machine Dynamics Mode Dynamic Parameters Direction x Mode no Mat freg Hz 500 on 500 Damping ratio 0 05 0 05 0 05 Measured tf file Modalresidue data files stiffness H m 1 00E 07 1 00E 07 1 00E 07 E lt Previous i Insert f Dynamic parameters Figure 3 1 63 Machine Dynamics Mode in Machine amp Tool Structural Flexibility tab 3 1 5 2 1 MEASURED T F FILE When you select the Measured t f file option in Machine Dynamics Mode given by Figure 3 1 63 you can include the dynamic parameters of the machine and tool to the simulation by downloading transfer function files frf which are measured in the x y and z directions by using the MalTF module of CutPro The transfer function files typically ASCII frf files have the real and imaginary parts of the transfer functions with corresponding the frequency values The FRF Type frame that opens with this option is show
188. s are selected MODES 2 PNTS 1 REALM 0 WN 476 834335632509 ZETA 4 04222522809633E 02 WN 602 222122314299 ZETA 1 90220641074104E 02 LOCNS 0 RESRE 7 40900299071828E 7 RESIM 2 76537568544895E 7 RESRE 1 02231217282896E 7 RESIM 8 15334757887865E 7 If Modal Model is Real Modes are selected MODES 3 PNTS 2 MAL Inc User Manual for CutPro exe 207 REALM 1 WN 731 707078645867 ZETA 9 94415717171146E 02 WN 806 213295945486 ZETA 3 32206599430105E 02 WN 1590 91649391174 ZETA 3 84238738626789E 02 LOCNS 0 LOCNS 20 MODSH 0 3291973 0 2874119 MODSH 0 135213 0 1240283 MODSH 0 1611198 0 1219372 MAL Inc User Manual for CutPro exe 208 6 7 USING MODAL PARAMETERS IN CUTPRO 1 In the Properties window of CutPro click the General tab 2 Select Dynamic vibrations as the Machine Cutter or Workpiece Model 3 Click the Dynamics tab 4 Select Modal residue data files as the Machine Dynamics Mode or Workpiece Dynamics Mode 5 Select the file s you want under X modal residue file or Y modal residue file amp Note You have to repeat the same modal analysis process for measurements in the Y direction as well For rigid directions just give a very large stiffness 10e6 by selecting Dynamic parameters MAL Inc User Manual for CutPro exe 209 6 8 TRANSFER FUNCTION MEASUREMENT FRF FILES For the typical transfer function measurement you can use hammer with force sensor and accelerometer or displacement sens
189. s modulus hardness tensile strength yield strength shear strength impact strength elongation reduction in area condition heat treatment melting point thermal expansion and electrical conductivity Also when defining a new material you must specify the force model and the corresponding cutting coefficients for that model F MAL Inc User Manual for CutPro exe 96 Material Viewer File New Material Afafenal Database Wirard iar tbe sorcemaedel Force Model f Average cutting coefficient f Orthogonal to oblique cutting transtormation f Venable cutting coefficient along the axial depth of cut C Bilinear force COC Exponential chip thickness f Sern mechanistic C High order mechanistic C Sandvik materials C Keinzle Show Equation Cancel Figure 3 1 70 The Force Model selection window for defining a new workpiece material There are two different materials in this list defined as Fixed Material and User Defined Material You are not allowed to make any modification on Fixed Material properties but can create your own material User Defined Material and enter all specifications of the material manually User defined materials are denoted with a preceding their name The following functions are available in order to edit materials Table 3 1 166 Buttons of Select a workpiece material New Create a new user defined material and display it in the Material Editor window View Edit View fixed materials
190. se Stability Lobes Analytical Complete Simulation Results ExO1_ Si gi stability Lobes Analytical E a Lj oO ear cL aE O 10000 20000 SU000 40000 SOOO0 Spindle Speed rpm ie fel EOS pws e 2 5504E 04 Options Coord s oom Reset Show All 3 250399 Figure 5 3 1 Sample Analytical Stability Lobes Five or more toolbar buttons are present on each Result Window Pak OPTIONS l Options Copy to Clipboard Add to Report Ctrl 4 Print Printer Setup More Options Cker 2 The Options toolbar button provides five options Copy to Clipboard Copies the graph onto the clipboard as a bitmap to save as a file click paste on a picture editing software Add to Report Adds the current result to the results Report Print Prints the graph on the current printer MAL Inc User Manual for CutPro exe 161 Printer Setup Brings up the standard Windows Printer Setup window allowing you to select the current printer and change other options such as paper size More Options Displays a tabbed dialog in which you can change the look of the graph See Graphppr hlp in the Help directory under your main CutPro directory for more details 5 522 X Y COORDINATES wif When this button is pressed you may left click on the graph Coords to display the coordinates of a specific point Se ee ZOOM When this button is pressed you may used the left mouse button to click and drag a zoom rectang
191. se this mode to simulate stability lobes within a naraw speed range Use this mode to simulate stability lobes within a narrow speed range Figure 2 3 4 Single Insert Analytical Stability Lobes mode is selected in General tab of Boring module MAL Inc User Manual for CutPro exe 32 This mode simulates the analytical stability lobes in the frequency domain by using orthogonal chatter stability theory to determine the stability border of the boring process which uses a boring head with a single insert The sample result window for the single insert analytical lobes mode is the same as the sample result window of the single analytical stability lobes mode of the 272 axis milling module ate 2 MULTI INSERTS MODULE Machining Process al Single Insert Figure 2 3 5 Multi Insert Boring module 2 3 2 1 STATIC ANALYSIS Multiple Inserts Boring Simulation Properties General Simulation Made lt gt v Back Mext Tabs Cancel OK General Machine amp Tool workpiece Cutting Conditions Static Analysis Simulates cutting forces spindle Power and torque when tool and workpiece can be assumed to be rigid Dynamic simulation Simulates cutting forces tool vibrations spindle power and torque in a time domain rc Analytical stability A fast analytical stability lobes prediction solved in a frequency lobes domain Figure 2 3 6 The Static Analysis mode is selected in General tab of the Multi I nsert Bo
192. t f 8 Tool vibration Untitled csF 9 Spindle Bending Moment Untitled cs More Windows A He Spindle Power Untitled csf gq i Spindle Torque Untitled csf S Spindle Bending Moment Untitled csf d Spindle Bending Moment Modal Machining Process loj x lol x O x Instantaneous Drilling E i J eels oll bet ll th n a B at oo 0 05 0 140 au ees fee a ee Figure 1 3 10 Window menu in CutPro MAL Inc User Manual for CutPro exe 26 Table 1 3 6 The drop down menu of Window command Close all Close all open graphs Figure Names Select the figure that you want to display on the screen 1 3 4 6 HELP W CutPro Untitled csf File Simulation Results Tools Window Help DO H Mew Open Save Propert Plot All Machining Process ol Contents and Index nae ne 7 gt Modal License Information About CutPro 7 0 Wisit CutPro Webpage Contact CukPro Support Figure 1 3 11 Help menu in CutPro Table 1 3 7 The drop down menu of Help command Contents and Index License Information About CutPro Visit CutPro Webpage Contact CutPro Support Display Help files for CutPro Allows you to click on an object in the CutPro graphical interface from either the content or the index or the find options and view the relevant help page s Activate CutPro modules with valid passwords you have obtained from
193. tability under flexible tool workpiece conditions Fast analytical stability lobes prediction solved in the frequency domain MAL Inc User Manual for CutPro exe 12 heal TURNING MODULE The Turning module is simulation software for optimum planning and troubleshooting of turning processes hala BORING MODULE The Boring module is simulation software for optimum planning and troubleshooting of boring processes The Boring module has two sub modules with the following features 1 2 3 1 SINGLE INSERT The Single Insert module is designed for quick analysis of single insert boring tools The Single Insert Sub Module has the following features Built in properties of a variety of materials such as Waspeloy Inconel Aluminum and Titanium alloys and Steels Accepts dynamic parameters of the machine tool and workpiece manually by you or in a variety of formats i e frf uff HP sdf cmp files created in CutPro or other commercial modal analysis software packages User specific material data entry Makes the following predictions and analysis Predicts static cutting forces spindle power and torque and radial deflection of the boring bar Stability Lobes Analytical prediction of chatter free radial depth of cuts and spindle speeds 1 2 3 2 MULTI INSERTS The Multi Inserts Sub Module has the same features as the Single Insert Sub Module with the following additional features Design of symmetric and asymmetric tools
194. tangential force N dFr differential radial force N dFa differential axial force N dS differential cutting edge length mm dz differential axial depth of cut mm h chip thickness mm KT tangential shearing coef Parameter KR radial shearing coef Parameter KA axial shearing coef parameter p tangential chip thickness order q radial chip thickness order r axial chip thickness order Kte tangential edge force coefficient N mm Kre radial edge force coefficient N mm Kae axial edge force coefficient N mm2 Ktc tangential shearing coefficient N mm 2 Krc radial shearing coefficient N mm2 Kac axial shearing coefficient N mm MAL Inc User Manual for CutPro exe 265 266 10 4 Appendix B4 Semi mechanistic model Equations dF K dS K h dz dF K dS K h dz dF K dS K h dz K K K 9 0 K k cosa k cosnsina k tanisin sina COS K k k cosg 1 COSI COSI K k tanicosar k sinn k tanicos sina dFt differential tangential force N dFr differential radial force N dFa differential axial force N dS differential cutting edge length mm dZ differential axial depth of cut mm chip thickness mm rake angle gt Q chip flow angle helix angle kn cutting pressure on rake face N mm kf cutting pressure rate on flank face Kte tangential edge force coefficient N mm Kre radial
195. the help file Graphppr hlp in the Help directory for the details regarding Graph Control Graph Control x Labels System About Polar Bubble Scatter Line Area 1 44 a a tl High Low Candlestick Bosw hisker Time Series Cancel Apply Now Help Figure 6 2 1 Graph Control 6 2 1 15 RECEPTANCE COUPLING RC gl function as Tools gt Receptance Coupling Please see Section 6 1 3D MODAL ANALYSIS MENU MAL Inc User Manual for CutPro exe 198 6 2 2 BOTTOM TOOLBAR 6 2 2 1 OPTI ONS Options Copy to Clipboard 4dd to Report Chrl 4 Print Printer Setup The Options toolbar button provides five options Copy to Clipboard Copies the graph onto the clipboard as a bitmap to save as a file click paste on a picture editing software Add to Report Adds the current result to the results Report Print Prints the graph on the current printer Printer Setup Brings up the standard Windows Printer Setup window allowing you to select the current printer and change other options such as paper size 6 2 2 2 MODES Tal When this button is clicked you may select and add modes hades on the graph Use the left mouse button to select the left most extent of a mode and the right mouse button to select its right most extent 6 2 2 3 X Y COORDINATES kali When this button is pressed you may left click on the Lords graph to display the coordinates of a specific point 6 2 2 4 ZOOM f
196. the process is stable for each simulated condition If stable it goes to the next higher depth of cut for the same spindle speed repeating the simulation otherwise it reduces the depth of cut This procedure goes on until it finds the critical depth of cut value for the stable cutting at the same spindle speed Then it increases the spindle speed and scans the critical depth of cut for the new spindle speed Due to the long computational time this simulation may take very long time depending on the specified spindle speed range In order to shorten this time it would be a wise decision you specify a short range of spindle speed where you potentially wish to operate the machine The time domain simulation is executed based on the exact kinematics of a milling process Due to this fact some nonlinearities MAL Inc User Manual for CutPro exe 37 such as the tool jumping out of the cut or nonlinear variation of the cutting coefficients are taken into account in the time domain Simulation This makes this simulation more accurate compared to the analytical simulation where the system is assumed to be linear 2 1 1 3 SINGLE ANALYTICAL STABILITY LOBES File Simulation Results Tools Window Help a W Properties Run Run Temp Plot All Pew Open Save Modal MalTF Simulation Properties p Garverz lt gt l E yY Simulabon Mode Back Next Tabs Cancel OE Machining Process General Machine amp Tool w
197. ting effects from both spindle shaft and bearings are considered in the model Timoshenko beam theory is used in the FE model which includes axial bending and torsional behavior of the spindle system The nonlinear bearing model is used to include effects due to preloads and spindle speeds SpindlePro has the following features MAL Inc User Manual for CutPro exe 16 Deflection at any location of the spindle reaction forces and moments at bearing and housing supports can be predicted under any static forces Damped and Undamped Modal Analysis The natural frequencies and mode shapes are sorted according to axial torsional and bending You can assign modal damping ratios for each mode from your own experience and the database Fast and user friendly interface to build the spindle model Performs Frequency Response Function FRF analysis Includes rotating effect on bearings and _ natural frequencies Predicts bearing forces under cutting loads Displays history of displacement velocity and acceleration under dynamic forces User friendly post processor 1 2 8 VIRTUALCNC Virtual CNC is a powerful module which provides a comprehensive simulation environment for CNC design engineers and users simulate a wide range of performance related properties of Cartesian Configuration CNC machine tools before the actual machining process This way expensive and time consuming trial and error cuts can be reduced
198. ton bo 200m in right button to 200m out and holding down the CTAL key click and drag to move the zoom centre oom Out Reset Print Close Figure 3 1 25 General endmill cutter geometry MAL Inc User Manual for CutPro exe 70 71 se Indexable Cutter Geometry loj x Use the lett mouse button to zoom in right button to zoom out and halding down the CTRL key click and drag to move the 200m centre Print Close Figure 3 1 26 Indexable cutter geometry Please refer to Section 10 5 Appendix A5 for the detailed illustrations of these tools 3 1 3 2 FLUTES In Machine amp Tool Tool Type tab you will also enter the parameters of the tool given as follows 3 1 3 2 1 NUMBER OF FLUTES ON THE TOOL Simply type the number of flutes in the text box After the number is entered the small figure next to the text box showing the top view of the tool is updated Flutes Number of flutes Figure Toal Figure 3 1 27 Number of flutes text box in Machine amp Tool Cutter Type tab 3 1 3 2 2 PITCH ANGLE TYPE ON THE TOOL MAL Inc User Manual for CutPro exe 12 Uniform Pitch Cutter Non Uniform Pitch Cutter Figure 3 1 28 Uniform and Non Uniform pitch cutters You can choose the pitch angle type on the tool The pitch angle type can be either uniform or non uniform For uniform pitch cutters the pitch angles are equal and are evaluated from the following expression 360 number of fl
199. ular on the graph Use the right mouse button to go back to the previous view 5 3 4 RESET y s Click this button to reset the graph s axes to their original ie Reset maximally zoomed out values oe fe PITCHES the mouse button to see the pitches corresponding to a specified first pitch If you right click a table is displayed on the graph illustrating the pitches If you left click the pitches are added to the Pitches button menu on the toolbar 5 Optimal Variable Pitch graph only Click on the graph with Pitches 5 3 6 CUTTING COEFFICIENTS Cutting Coets Cutting Coefficient Identification graph only Click this button to see the cutting coefficients associated with the graph MAL Inc User Manual for CutPro exe 162 You may then save these coefficients as a user defined workpiece material smeT FFT FFT Single Time Domain graphs only Click this button to use Fourier Transform to see the graph in frequency domain 5 4 PLOTS A particular graph can be plotted individually as described in Section 4 2 Each module has its own set of available plots The following is a description of each type of plot 5 4 1 MILLING MODULE PLOTS 5 4 1 1 MAXI MUM TEMPERATURE HISTORY ALONG THE FULL CUTTER ROTATI ON SE Maximum Temperature History Along the Cutter Rotation Untitled e Maximum Temperature History Along the Cutter Rotation ue fWaximum Temperature lt flax Allowable Temperature iT
200. utes For the tools with non uniform pitch distribution you must enter the pitch angles between successive flutes The Pitch angles must be bigger than zero and the summation of all pitch angles must be 360 fe Uniform pitch flutes are spaced equally C Nor uniform pitch Pitch 4 TOR Figure 3 1 29 Pitch type of the tool in Machine amp Tool Cutter Type tab 3 1 3 2 3 HELIX ANGLE TYPE ON THE TOOL You can choose the helix angle type on the tool It can be either uniform or non uniform For the tools with uniform helix angle all the flutes have the same helix angle For the tools with non uniform helix angle you must enter the helix angle for each flute The helix angles must be bigger than zero and less than 90 Uniform helis all flutes have the same helix angle C Son uniform helis Helis c 1 js 0 Figure 3 1 30 Helix angle type of the tool in Machine amp Tool Cutter Type tab 3 1 3 2 4 RUN OUT DEVIATIONS OF FLUTES Run outs are defined as deviations from the ideal design coordinates of the cutter You digitize the cutter at small increments along the axial direction and provide the digitized envelope in a run out file Use run out deviations File Figure 3 1 31 Run out deviations of flutes in Machine amp Tool Cutter Type tab F MAL Inc User Manual for CutPro exe 73 By checking the box next to Use run out deviations in Figure 3 1 31 you can include the effects of run out dev
201. utting coefficient model and its parameters Average cutting coefficient model Variable cutting coefficient model Orthogonal to oblique cutting transformation Bi linear force model Exponential chip thickness model Semi mechanistic model High order force model Sandvik force model Kienzle force model Cutting properties Notes Save Cancel PROPERTIES MAL Inc User Manual for CutPro exe 98 Material name F sample Material Description Composition Figure 3 1 72 Properties frame in Material Editor window Scroll down in Properties frame to define the specifications of the workpiece material given in the following table Table 3 1 177 Specifications of workpiece material Material name Description Composition Density g cm 3 Thermal conductivity W mK Specific heat capacity J kgK Young module N m2 Hardness HB Tensile strength N m2 Yield strength N m2 Shear strength N m2 Impact strength N m2 Elongation Reduction in area Condition Heat treatment Melting point C Thermal expansion 10e 6 C Flectrical conductivity CUTTING COEFFICIENT MODEL In the Cutting Coefficient Model frame you see the cutting coefficient model you chose on the Workpiece Material tab and define the required parameters for that model The Cutting Coefficient Model frame is shown in the following figure MAL Inc User Manual for CutPro exe 99 Cutting Coefficient
202. w any changes you have made to the materials will be lost amp Below you can find short descriptions of material force model listed on this tab You can see the definition of any selected model by clicking Show Equation button Under each model presented above you will be finding predefined material data If the material you wish to simulate is not in any material list you can identify the material data by simply doing average cutting coefficient identification Note that you can also define the material data in any model you wish using NEW button When you click NEW button Material Editor Window will show up You can now enter the equations of cutting coefficients or parameters by using Equation Editor Note that each force model has its own definition You can see this by clicking Show Equation If you wish to add a new material in any model the equation must meet the definition of the model specified in Equation window amp Note You can put in additional information regarding the test conditions under which you developed the data material s technical specifications and etc MAL Inc User Manual for CutPro exe 114 3 1 7 WORKPIECE STRUCTURAL FLEXIBILITY TAB Plot ll CutPro Untitled csf Fie Simulation Results Tools Window Help o k ih New Open Save Properties Run lin op Malb4Q SpindleProa Animation Run Temp Modal Machining REC era E Process Workpiece lt gt hel
203. window Table 3 1 4 The drop down menu of File command on Run out Value Editor window Open Open an existing run out cro file Save Save the currently open run out file under the same name Save As Save the currently open run out file under a different name Exit Exit the Run out Editor window EDIT COMMAND 10 x File Edit Units ou Ctrl s of the run out values is Micrometer aes ae Flute 3 Flute 4 Delete Del Insert Row Shift Ins Delete Row Shift Del ies Hie e ee EAN 5 E Figure 3 1 35 Edit command on Run out Value Editor window Table 3 1 5 The drop down menu of Edit command on Run out Value Editor window Cut Cut the selected range of cells MAL Inc User Manual for CutPro exe 75 Copy Copy the selected range of cells Paste Paste the clipboard contents onto the table at the selected place Delete Delete the selected range of cells Insert Row An empty row at the selected place Delete Row Delete the selected row UNITS COMMAND io xl File Edit Units Millirmetres Cbrl M z s Micrometres Ctrl U e run out values Micrometer Flute 4 Ley 7 OT Ee po a Figure 3 1 36 Units command on Run out Value Editor window Table 3 1 6 The drop down menu of Units command on Run out Value Editor window Millimeters Display all measurements in millimeters mm Micrometers Display all measurements in micrometers um amp The Units menu
204. with user defined insert geometry Makes the following predictions and analysis Simulates the cutting forces in three dimensions with Spindle power and torque prediction when the tool and workpiece can be assumed to be rigid or for dynamic tool and workpiece condtions Fast analytical Stability Lobes prediction solved in the frequency domain MAL Inc User Manual for CutPro exe 13 1 2 4 MODAL ANALYSIS The Modal Analysis module determines the dynamic characteristics and mode shapes of a machine tool system from frequency response functions FRF that are measured at various geometric locations on a system using transfer function measurement software MalTF an impact hammer and an accelerometer The Modal Analysis module has the following features Predicts natural frequency damping ratio and stiffness of each mode from FRF measurements at the tool tip Receptance coupling of defined end mill with the measured spindle tool holder Receptance coupling tool allows you to obtain the assembly response from the responses of the substructures i e spindle and tool by combining two transfer functions together Flexible tool analysis allows you to predict the transfer function on a slender tool tip where accurate measurement cannot be performed due to multiple hits Predicts and displays mode shapes 1D 2D and modal parameters from FRF measurements are made along the structure axis i e spindle thin webs machine too
205. x angle rad Z_ ns insert depth of cut This option is for inserted cutter Vc cutting speed m min ins num insert number This option is for inserted cutter a_n rake angle rad flu num flute number af relief angle rad m pi 3 14159265358979 The following math operators are available in the Equation Editor window See Figure 3 1 75 Table 3 1 190 Math operators in the Equation Editor window Addition Subtraction i Multiplication Division Power e g x a Parentheses amp Note that certain restrictions are placed on valid equations Whenever you click Save your equation will be automatically checked for errors You will not be allowed to save an invalid equation Click on Save to save changes you made in the equation and close the Equation Editor window Click Cancel to exit the Equation Editor window without saving any changes Note that if you enter the cutting coefficients as an equation your simulation speed will be more than ten times slower in any time domain simulations depending on your equations If it is not necessary do not enter an equation for cutting coefficients MAL Inc User Manual for CutPro exe 102 CUTTING PROPERTIES Cutting Properties Tool geornetry PO Tool ro fT Tool manufacturer fT Cutting type PO Cutting condition f Dry Lubricated Figure 3 1 76 Cutting Properties frame in the Material Editor window In the Cutting Properties frame you

CutPro

Contents

Download Pdf Manuals

Related Search

Related Contents