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and cooling, composites manufacturing and others. In most cases, these are still being performed by dedicated simulation specialists. So it is our belief that the democratization of CAE, while underway, has yet to reach its full potential.”


Optimized Drilling Machining expensive corrosion-


resistant materials is extremely hard on drills, and a recent study by researchers at the Technical University of Dortmund (Dortmund, Germany) used fl uid fl ow and structural analysis tools from Ansys Inc. (Pittsburgh) to analyze process coolant fl ow distribution and achieve longer tool life. At the Technical University of


Dortmund’s Institute of Machining Technology (ISF), a research team led by Professor Dirk Biermann analyzed methods to extend the life of drills for use on the superalloy Inconel 718. The low thermal conductivity of this alloy means that a large amount of heat must be transported away from the boring zone using external methods, or the tool can become deformed. This can lead to poor bore quality or breakage of the carbide drill bit. Relatively low drill speeds under 50 m/min are used to keep temperatures lower in the cutting zone, but a liquid coolant is still required. To direct the cool- ant fl uid where it is needed, it is pumped through two tiny channels inside the land, the solid, helical pattern of the drill bit. To understand the complex interaction between the drill structure, the coolant fl uid and the Inconel workpiece, the ISF team used simulation tools from Ansys for process optimization by performing a fl uid–structure interaction (FSI) analysis. The process included creating completed fl uid meshes, then the engineers used Ansys CFX computational fl uid dynamics (CFD) software to model the distribution of coolant through the fl uid domain. The team also used Ansys Mechanical with


an added boundary condition of the coolant forces calculated by CFX to complete the FSI analysis. Including all of the different CFD and Mechanical simulations, ISF completed its computa- tional analysis within four weeks. “Drilling into an Inconel alloy


Cut Precision Internal Threads The New Method To


Leistritz has developed internal whirling, a process to cut long internal threads without tilting the tool at helix angle. The method utilizes the bore to support the carbide or CBN cutting tool for extremely accurate profiles and overall geometries. This special


purpose machine, model LWN-120-IW, has high frequency oscillation to cut threads with high helix angles and/ or multiple starts. Give us a call or send us an email with your specific application, we know you will be impressed with this outstanding machine’s capabilities.


Leistritz Advanced Technologies Corp.


˞ˣ ñ]4©¶½¶ œ¶¤44¶ɗ ß~~40 ~4ɗ ijĤ ˤ˞ ɡ 201 934-8262 ËËËɕ~4a©¶¤a¶Ú%¤¡ɕ% ɡ staff@leistritzcorp.com


June 2017 | AdvancedManufacturing.org 65


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