Rapid metal cutting simulation software

Metal
cutting is used in all metal machining processes (e.g. turning, milling and boring) and
lies at the heart of the global manufacturing industry. However, modelling the physics of
metal cutting reliably and quickly has always been difficult. This means that designing
efficient manufacturing processes has remained an inexact science, generally relying on
collected experience and/or time consuming and costly trial and error testing. With the metal
machining industry estimated to be worth in excess of $675 billion per annum worldwide, the
scope for significant cost savings is clearly huge.
The goal of this project is to demonstrate that the recently developed discontinuity layout
optimization (DLO) numerical modelling technique can be applied to metal cutting
simulation, potentially allowing the process to be modelled far more reliably than using
traditional hand analysis methods, and an estimated 1000x more quickly than using current-
generation finite element based techniques. This has the potential to give manufacturing
engineers the ability to rapidly determine optimum operating conditions, thereby
revolutionising the way in which machining processes are designed