Efficient Analysis of Milling Processes for the Manufacturing of Forming Tools Using a Multi-Scale Simulation System

Zabel, A.1, a; Odendahl, S.1, b; Peuker, A.1, c

Institut für Spanende Fertigung, Technische Universität Dortmund, Baroper Str. 303, 44227 Dortmund

a) zabel@isf.de; b) odendahl@isf.de; c) peuker@isf.de


In order to evaluate the process stability and safety of NC milling process for the manufacturing of forming tools during the process planning phase and, thereby, prevent extensive experimental investigations, a preceding simulative analysis of the process is advisable. For a comprehensive analysis and optimization of the milling process, the simulation system should, on the one hand, be able to provide as much information as possible, but it should, on the other hand, also allow multiple simulation runs with varying process parameters in a reasonable time frame. This can be achieved by applying a multi-scale modeling concept with different levels of detail, which offers different optimization options with regard to the run-time of the simulation without limiting the prediction capabilities. The ability of the simulation system to calculate stability charts for milling processes is utilized for the process planning of the NC milling of a springback-compensated deep-drawing die in order to ensure process reliability.


Milling, simulation, multi-scale modeling, run-time optimization, springback compensation


In: Sonderforschungsbereich 708 Systeme der Blechformteilefertigung - Erzeugung, Modellierung, Bearbeitung - 6. Öffentliches Kolloquium, 15.11. 2013, Dortmund, Tillmann, W., Baumann, S. (Hrsg.), ISBN 978-3-86975-086-6, S. 107-114