Rheinische Fachhochschule Köln

Simulation Assisted Design & Dimensioning of Chip Breaking Geometries on Profile Tools

Rheinische Fachhochschule Köln (RFH) collaborated with an industrial partner, Schwanog Siegfried Güntert GmbH, to design and develop custom profile tools with chip breakers. The project involves evaluating different types of chip breakers using AdvantEdge. Parameters such as temperature, stress, strain, and more, were compared to the chip’s simulation output for different types of chip breaker designs to make informed decisions at every step.

CHALLENGE

Chip breaker geometries are commonplace in grooving tools. However, profile tools, with long contact area, present a unique challenge for managing chip morphology and flow. There is an added level of complexity when these profile tools are used for machining ductile materials that do not lend themselves for chip breakage. 

APPROACH

RFH research team first focused on using 2D simulations was used to verify the chip breaking process for each design of the chip breaker. This yielded quicker results and helped narrow down the selection of chip breakers for detailed analysis using the 3D simulations. Once the team settled in on the basic geometry for the most effective chip breaker design, STEP file models were imported in AdvantEdge to study the effects of the chip fold at the internal corners and their role in chip breakage.

IMPACT

The combined approach of using 2D and 3D simulations helped drive quicker decision making for selecting the final prototype designs.

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