MILLING MODULE

Milling module is highly accurate and the most comprehensive simulation software for optimum planning and troubleshooting of milling processes.

Milling module has two sub modules with the following features:

2.5 Axis Milling Module

Advanced Milling Module has the following features:

• Simulates regular cyclindrical endmills, variable pitch cutters, ball endmills, indexable cutters, serrated cutters and endmills with any user-defined geometry.
• Has built-in properties of variety of materials such as Waspaloy, Inconel, Aluminum and Titanium alloys, Steels, and standard Sandvik materials.
• Accepts dynamics parameters of the machine tool and workpiece maually by the user or in 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:
  
  
  • Cutting forces in three directions
  • Vibrations in the feed and normal directions (x,y)
  • Surface finish caused by feed marks, static and dynamic (chatter) deflections
  • Stability Lobes: Most accurate predictions of chatter free axial and radial depth of cut and spindle speeds
  • 3D Chatter stability diagrams
  • Design and analysis of inserted/indexable cutters
  • Design and analysis variable geometry helical end mills
  • Design of variable pitch cutters tuned to a specific material and spindle for chatter suppression
  • Design and analysis of serrated cutters
  • Experimental modal analysis at the tool tip (automatic identification of natural frequencies, modal stiffness and damping ratios)
  • Automated identification of cutting constants from milling tests
  • User specific material data entry
  • Simulates stability lobes and forces for a batch of conditions with multiple immersions
    

Plunge 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
  • Fast analytical stability lobes prediction, solved in the frequency domain
  • Dynamic simulation of forces, vibrations, torque, and power consumption in the time domain