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Physics-Based Optimization of OMC Machining

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Physics-Based Optimization of OMC Machining


Physics-based optimization of machining has long been used in manufacturing metal components, resulting in higher quality parts, extended tool life and significant reductions in machine cycle time. Detail-level analysis includes physics-based finite element simulation which provides understanding of the tool, workpiece and chip throughout the machining process. Toolpath level analysis and optimization can be done at many levels from a simplistic volume-based material removal strategy to a more comprehensive material-based strategy. The direct application of these models to composite components has proven challenging, resulting in high cost, physical testing.Third Wave Systems (TWS) has extended its simulation capabilities to organic matrix composites (OMC) and the difference between OMC and metals required developing a fracture plane model and a more complex material model for detailed level simulation of material cracking and fracture. TWS has successfully modeled and optimized OMC machining on a variety of OMC materials and full-scale components on the F135 and F-35. The application of OMC material models to toolpath level analysis reduced overall cycle time and engineering costs. Current and future work includes advancing technologies developed for OMCs to model ceramic matrix composites (CMCs). TWS has also started enhancing OMC material models to simulate behaviors of Ox/Ox and SiC-based CMCs.


Author: Qinwu Xu, Jon Wadell, and Rich Keele


Conference: SAMPE Seattle 2017


SKU/Code: SE17--0572

Pages: 17

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