Machining

Milling is today the most competent, productive and flexible-manufacturing methods for complicated or sculptured surfaces. Ball end tools are today used by the manufacturing industry for the machining of 3D free-form surfaces for dies, molds, various parts, such as aerospace components, etc. Milling data, such as surface topomorphy, surface roughness, non-deformed chip dimensions, cutting force components and dynamic cutting behavior, are very helpful, especially if they can be computationally accurately produced by means of a simulation program.

Twist drills are geometrical complex tools and thus various researchers have adopted different mathematical and experimental approaches for their simulation. The present research acknowledges the increasing use of modern CAD systems and subsequently using the API (Application Programming Interface) of a typical CAD system, drilling simulations are carried out.

The utilization of abrasive waterjet (AWJ) cutting/drilling, and in particular its application into hard-to-cut materials, is growing. However, the mechanics of AWJ cutting is complex; the material removal process is not fully understood and, consequently, it has not been accurately modeled. In the current study, work was undertaken to mesh in a first stage the waterflow into the waterjet nozzle in order to use the finite element (FE) method to simulate the pure waterjet flow. The main objective is to investigate and analyze in detail the workpiece material behavior under waterjet impingement; a non-linear FE model (using LS-DYNA 3D code) has been developed, which simulates the erosion of the target material caused by the high-pressure waterjet flow.