Finite element analysis for tool designers

There is a universal truth in corporate success: constant innovation is required. As global competitiveness continues to escalate, cutting tool designers face a pressing need to fast track their R&D initiatives while maintaining quality.

Finite element analysis software provides toolmakers with a virtual testing environment for evaluating tool designs. Whether conducting a side-by-side comparison of different helix angles or evaluating chipbreaker geometries, manufacturers can utilize FEA to more efficiently and affordably recognize promising prototypes. FEA software can also avoid costs associated with testing faulty prototypes by identifying top performers without trial-and-error testing.

FEA simulations provide more data than trial-and-error tests, including cutting forces, temperatures and stresses. This reduces design iterations and helps get tools to market faster.

Courtesy of Third Wave Systems

Third Wave Systems’ AdvantEdge FEM finite element analysis software generates a temperature profile for a drill.

“By utilizing FEA, we estimate that tooling costs for a project can be reduced 30 percent and development time can be reduced at least 15 percent compared to proceeding via conventional trial and error,” said T.J. Long, engineering manager of indexable milling systems at Kennametal Inc., Latrobe, Pa.

In addition to providing more advanced modeling capabilities, FEA technology has become more industry-specific. However, this has had a polarizing effect on software applicability; technology that becomes an asset to one market may no longer be the best resource for another. FEA software best suited for toolmakers must offer the ability to quickly set up and dynamically analyze cutters under specific machining conditions.