Burr formation in curved-surface drilling
and drilling of intersecting holes
Machining of composite materials
Burr formation in drilling of multilayer
materials
DEFORM
Background
Deform, short for Design Environment for
Forming, is a product of Scientific Forming
Technologies Company (SFTC) and is a
commercially available FEM solver that can be
applied to several manufacturing processes.
Deform's original area of specialty was in
metal forming operations like forging. It has
since expanded to include modules that
support machining operations.
Advantages
Deform’s machining modules can be used to
quickly set up standard machining processes
like turning, milling and drilling. The user has
to supply the workpiece and tool geometry as
well as the process parameters. The solver
then uses a standard solver configuration and
finds the solution. Alternatively, the user has
the ability to adjust solver parameters like
mesh-size, nodal boundary conditions, and
tool-workpiece interaction properties, for
example. Given that many of these
parameters remain constant from one
simulation to the next, the pre-programmed
modules can work very effectively. However,
for detailed research and analysis, the high
level of control is desirable. Fortunately,
Deform can accommodate both modes of
simulation.
Deform also has an extensive material library
containing models of several common
materials and alloys. The program also has
the capability of defining new materials based
on stress/strain data and other key material
properties. This contributes to the usability of
the program to simulate actual process
conditions and increases its applicability.
Deform uses adaptive meshing controls to
accommodate high workpiece deformations
that are very common in machining. This
ensures the accuracy of the solution as well as
ensuring that an optimal number of elements
are used overall. That is, more elements are
used where strain rates are high and there is
large deformation and fewer elements are
used little deformation is takes place.
Disadvantages
Deform's drilling module is still in a beta
version and there are a few deficiencies that
are being addressed. The workpiece tends to
demand more and more elements as the
simulation progresses, which causes the
simulation to run slower with time. In addition,
the simulation will stop periodically and the
mesh size needs to be adjusted by the user.
There are several fine points which
accompany the learning curve for Deform, but
the learning process is not tedious.
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