Physics-based CAE solutions for companies that machine

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Physics-based CAE solutions for companies that machine

OUR MACHINING SOLUTIONS

A dynamic user interface in AdvantEdge and Production Module simulate part machining and display tool position with corresponding forces, power consumption, and more — helping users better understand their machining processes and identify opportunities for improvement.

AdvantEdge: Finite Element AnalysisAdvantEdge is used to understand the “whys” of tool performance by providing a virtual testing environment for evaluating tool designs. Users efficiently and affordably recognize promising prototypes and top performers while reducing design iterations and trial-and-error testing.

» Define tool geometry or import from CAD program » Select tool and workpiece materials » Input cutting conditions » Run simulations » Compare simulation results for optimizing cutting conditions or tool geometries

» Analyze temperature and stress profiles to gage reductions in tool wear

» Use chip formation to predict improved chip evacuation » Evaluate force plots to lower cutting forces and power consumption

HOW IT WORKS

Production Module: NC OptimizationProduction Module is a premier NC toolpath optimization software that integrates physics-based material models, CAD/CAM data, tooling and workpiece geometries to analyze and optimize machining processes. Our machining solution allows users tobalance forces, optimize feedrates for time reduction*, reduce air cutting time, visualize peak tool temperature and more, all while maintaining tool life.

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

» User imports toolpath and sets machining optimization limits

» Production Module balances tool loads

HOW IT WORKS Load leveling opportunity to reduce cycle time.

Damaging force spikes removed.

Feed rates optimized across toolpath.

Air -cut feed rates optimized

Milling Simulation

*Aerospace engine customers typically see 20% or more improvement in Turning and 25% or more in Milling, with improved tool life. Aerospace structures customers typically see 25% or more in Titanium and 15% in Aluminum, with improved tool life. For automotive and other industries, users typically see 10-15% range in cycle time improvement. All percentages are dependent on material and complexity of parts and baseline toolpath.

ENGINEERING SERVICES

Material ModelingAdvantEdge and Production Module have an expanding library of more than 140 materials that have been developed and validated using proprietary material characterization technology that our engineers convert into custom material models. The state-of-the-art technology and Third Wave Systems’ expertise ensures the user experience is a smooth transition into future process analyses.

The epicenter of Third Wave Systems’ success is its Testing & Validation Center (TVC), a research and development lab that enables engineers to continually validate the software. The majority of Third Wave Systems’ engineering services are performed at the TVC, utilizing a five-axis machining center, measurement and inspection capabilities, which range from surface finish measurement to cutting force data collection, and much more.

TESTING & VALIDATION

Equipment & Resources

» MACHINING: Mori Seiki NH6300 DCG five-axis horizontal machining center, 30 kW, 8000 RPM high torque direct drive CAT-50 spindle, 1 m x 1 m x 1.3 m work envelope, Fanuc series 16i controller, 70 bar high pressure coolant system

» DATA ACQUISITION: National Instruments X Series, USB 6343 32 channel data acquisition board, 500 kHz sampling rate, Matlab software with data acquisition and signal processing toolboxes

» SOFTWARE: Dassault Systèmes CATIA, Autodesk AutoCAD, CGTech VERICUT, Siemens NX

» DIMENSIONAL MEASUREMENT: Renishaw MP700 optical transmission probe

» VIBRATION MEASUREMENT: MetalMAX Modal Analysis System

» CUTTING FORCE/POWER: Kistler 9255B table mounted dynamometer; Kistler 9526C mini-dynamometer; Kistler 5070A and 5080 multichannel charge amplifiers; Kistler 9125A rotating multi-component dynamometer, Caron TMAC spindle power

» TOOL WEAR ASSESSMENT: Flexbar Optiflex digital microscope for 220x magnification with image capture software

» SURFACE FINISH: Taylor-Hobson Surtronic 25 system

Training & ImplementationThird Wave Systems engineers help our users implement process optimization by traveling globally to customer facilities to teach users about AdvantEdge and Production Module in an interactive on-site format. Training sessions can be customized, ranging from large events or specific one-on-one sessions.

Z Force vs. Time

Z Fo

rce

(N)

Time (sec)

-500

OptimizedBaseline

0

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

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

THIRD WAVE SYSTEMS6475 City West Parkway Minneapolis, MN USA 55344 Tel: [001] 952-832-5515www.thirdwavesys.com | sales@thirdwavesys.com

INTERNATIONAL DISTRIBUTIONISBE GmbHBahnhofstrasse 2970372 StuttgartGermanyTel: [49] 711-223-29870www.isbe.de

OSIN TECHNOLOGYRoom 1129, Unit B, Xinhualianligang BuildingNo. 26 Jiuxianqiao zhong lu, Chaoyang District100016 BeijingChinaTel: [860] 010-6436-8976 www.osintech.com

UNITED FORCE CORPORATIONRoom 1-1-1201, LingHang International CenterGuangqumen Nanxiaojie, Chongwen District100061 BeijingChinaTel: [86] 010-6717-4868www.ufc.com.cn

OBP ENG CORPORATIONB-1606, Intellige-II,Jeongjail-roBundang-gu, Seongnam-si, Gyeonggi-do463-841South KoreaTel: [82] 31-713-4078www.obp.co.kr

ITOCHU TECHNO-SOLUTIONS CORPORATION (CTC)Kasumigaseki Building, 3-2-5 Kasumigaseki,Chiyoda-ku, Tokyo 100-6080 JapanTel: [81] 03-6203-7344www.engineering-eye.com