Advantedge 7 1

ADVANTEDGE 7.
1
USER’S MANUAL
SEE MORE. KNOW MORE.

Copyright © 1995-2015, Third Wave Systems, Inc. All rights reserved worldwide.
No part of AdvantEdge software or documentation may be reproduced,

transmitted, transcribed, stored in a retrieval system, or translated in any form
without the express written permission of Third Wave Systems.
AdvantEdge © Third Wave Systems Windows © Microsoft

CorporationNX® © Siemens Product Lifecycle Management Software Inc.
All other product names mentioned herein are trademarks or registered

trademarks of their respective owners.
SEE MORE. KNOW MORE.
TABLE OF CONTENTS
Introduction
AdvantEdge Benefits .................................................................................................... i
AdvantEdge Components .............................................................................................. i
AdvantEdge Features................................................................................................... ii
Tooling Capabilities................................................................................................ ii
Machining Parameters ............................................................................................ ii
Minimum System Requirements ................................................................................... iv
AdvantEdge 2D (minimum).................................................................................... iv
AdvantEdge 3D (minimum).................................................................................... iv
Parallel Computing (minimum) ................................................................................ v
Supported Platforms .............................................................................................. v
Installation................................................................................................................. v
Regional Settings (International Customers Only) ...................................................... v
Keyboard Shortcuts ............................................................................................... v
2D Getting Started
Start a New Project ..................................................................................................... 1
Identify the Process Type ............................................................................................. 1
Turning ................................................................................................................ 2
Milling.................................................................................................................. 3
Sawing................................................................................................................. 3
Broaching ............................................................................................................. 3
2D Graphical User Interface (GUI) ................................................................................. 4
Select Units................................................................................................................ 4
Set Preferences .......................................................................................................... 5
Batch Processing ................................................................................................... 5
I
Default Folder....................................................................................................... 6
Metadata ............................................................................................................ 6
3D Getting Started
Start a New Project..................................................................................................... 7
Identify the Process Type ............................................................................................ 7
Turning ............................................................................................................... 9
Milling ................................................................................................................. 9
Drilling ............................................................................................................... 11
Orbital Drilling ..................................................................................................... 11
3D Graphical User Interface (GUI) ............................................................................... 11
Workpiece-Tool Display......................................................................................... 13
Select Units .............................................................................................................. 15
Set Preferences ......................................................................................................... 15
Batch Processing.................................................................................................. 16
Default Folder...................................................................................................... 16
2D Tool Setup
Standard Tools.......................................................................................................... 17
Custom and Imported Tools ........................................................................................ 18
Create a Custom Tool ........................................................................................... 18
Import a Custom Tool........................................................................................... 19
Custom Tool Editor............................................................................................... 20
Dynamic Tool Inputs .................................................................................................. 21
Elliptical Tool Vibration and Vibration Assisted Machining ...........................................22
Stiffness and Damping.......................................................................................... 24
Vertical Velocity ................................................................................................... 24
Tool Material............................................................................................................. 25
Standard Tool Materials ........................................................................................ 25
Tool Coatings ...................................................................................................... 25
Custom Tool Materials .......................................................................................... 26
Tool Wear................................................................................................................. 27
Standard Wear Model ........................................................................................... 27
Custom Wear Model ............................................................................................. 28
Usui’s Wear Model................................................................................................ 29
User-Defined Wear Model ...................................................................................... 30
Tool Mesh Viewer ...................................................................................................... 31
Selective Element Plotting ..................................................................................... 32
3D Tool Setup
II
Turning Tools ........................................................................................................... 33
Oblique Turning Tool ............................................................................................ 33
Nose, OD, and Face Turning Tools ......................................................................... 34
Wiper Inserts (Nose Turning Only) ......................................................................... 34
Milling Tools ............................................................................................................. 35
Side Cutting Solid End Milling Tool ......................................................................... 35
Side Cutting Indexable Milling Tool ........................................................................ 35
Solid Milling Tool for All Other Process Types ........................................................... 36
Indexable Tool for All Other Process Types .............................................................. 38
Stacked Milling Tools............................................................................................ 38
Runout............................................................................................................... 39
Differential Pitch.................................................................................................. 40
Drilling Tools ............................................................................................................ 41
Solid Drilling Tool ................................................................................................ 41
Indexable Drilling Tool ......................................................................................... 45
Orbital Drilling Tools .................................................................................................. 45
Grooving Tools ......................................................................................................... 46
Standard Grooving Tool........................................................................................ 46
Cone Tool ........................................................................................................... 47
Boring Tools ............................................................................................................. 47
Tapping Tools ........................................................................................................... 48
Custom Tools ........................................................................................................... 48
Custom Tool Editor .............................................................................................. 48
Custom Oblique Turning Tools ............................................................................... 53
Custom Nose, OD, and Face Turning Tools .............................................................. 54
Custom Boring & Indexable Milling Tools................................................................. 57
Stiffness and Damping............................................................................................... 58
Tool Material ............................................................................................................ 59
Cutter Body Material ............................................................................................ 59
Tool Wear ................................................................................................................ 60
Tool Deflection ......................................................................................................... 60
2D Workpiece Setup
Standard Workpieces: Turning/Sawing/Broaching.......................................................... 63
Initial Stress ....................................................................................................... 63
Standard Workpieces: Up and Down Milling .................................................................. 64
Workpiece Materials .................................................................................................. 65
Standard Workpiece Materials ............................................................................... 65
Custom Workpiece Materials ................................................................................. 66
Custom Workpieces: Turning/Broaching/Sawing ............................................................ 66
Composite Workpieces: Turning/Broaching/Sawing........................................................ 67
III
3D Workpiece Setup
Turning Workpieces ................................................................................................... 71
Oblique Turning Workpieces .................................................................................. 71
Nose Turning Workpieces ...................................................................................... 72
OD and Face Turning Workpieces ........................................................................... 73
Milling Workpieces ..................................................................................................... 74
Side Cutting Workpieces ....................................................................................... 74
Corner Cutting Workpieces .................................................................................... 74
Face Milling Workpieces ........................................................................................ 76
Ramp Milling Workpieces....................................................................................... 76
Plunge Milling Workpieces ..................................................................................... 77
Pocket Milling Workpieces ..................................................................................... 77
Drilling Workpieces .................................................................................................... 78
Standard Drilling Workpieces ................................................................................. 78
Drilling Workpieces with Pilot Holes ........................................................................ 78
Composite Drilling Workpieces ............................................................................... 79
Oblique Drilling Workpieces ................................................................................... 80
Grooving Workpieces ................................................................................................. 80
Boring Workpieces ..................................................................................................... 82
Tapping Workpieces ................................................................................................... 82
Orbital Drilling Workpieces .......................................................................................... 83
Truncated Orbital Drilling Workpieces .................................................................... 84
Advanced Workpiece Setup Options ............................................................................. 85
Initial Meshing Parameters .................................................................................... 85
Adaptive Remeshing Parameters ............................................................................ 86
Workpiece Materials................................................................................................... 87
2D External File Imports

DXF Tool Import ........................................................................................................ 89
DXF Tool Viewer .................................................................................................. 90
Custom Tool Editor............................................................................................... 91
3D External File Imports

NASTRAN Tool Import ................................................................................................ 96
Exporting NASTRAN Files ...................................................................................... 96
Importing NASTRAN Files ...................................................................................... 97
STL/VRML Tool Import ............................................................................................... 98
Exporting STL/VRML Files...................................................................................... 99
Importing STL/VRML Files ..................................................................................... 99
STEP File Import ..................................................................................................... 102
IV
STEP File Components.........................................................................................103
Importing STEP Tool Files ....................................................................................103
STEP Analyzer....................................................................................................110
Importing STEP Workpiece Files ...........................................................................123
Preparing STEP Files for AdvantEdge Import...........................................................123
Healing Imported STEP Files ................................................................................126
2D Process Setup
Turning/Sawing/Broaching ........................................................................................129
Up and Down Milling.................................................................................................130
Friction Coefficient ...................................................................................................130
Coolant Modeling .....................................................................................................131
Temperature Dependent Coolant ..........................................................................132
Immersed Coolant ..............................................................................................132
Excluded Tip Vicinity Coolant................................................................................133
Focused Coolant .................................................................................................134
Focused Coolant: Model Pressure..........................................................................135
Process Options .......................................................................................................137
3D Process Setup
Turning ..................................................................................................................139
Oblique and Nose Turning....................................................................................139
OD and Face Turning ..........................................................................................140
Milling ....................................................................................................................140
Side Cutting.......................................................................................................140
Corner Cutting ...................................................................................................141
Face Milling .......................................................................................................142
Ramp Milling ......................................................................................................142
Plunge Milling.....................................................................................................143
Pocket Milling.....................................................................................................144
Drilling ...................................................................................................................144
Grooving.................................................................................................................145
Boring ....................................................................................................................146
Tapping ..................................................................................................................147
Orbital Drilling .........................................................................................................147
Process Type windows ..............................................................................................149
Friction Coefficient ...................................................................................................150
Coolant Modeling .....................................................................................................150
Process Options .......................................................................................................150
V
Custom Materials
Constitutive Model ................................................................................................... 151
Power Law ........................................................................................................ 152
Drucker Prager .................................................................................................. 152
User-Defined ..................................................................................................... 153
Heat Transfer.......................................................................................................... 153
Strain Hardening ..................................................................................................... 154
Thermal Softening ................................................................................................... 156
Rate Sensitivity ....................................................................................................... 157
Elastic.................................................................................................................... 159
Damage ................................................................................................................. 160
Conductivity ........................................................................................................... 163
Heat Capacity ......................................................................................................... 164
Thermal Expansion .................................................................................................. 166
Temperature Dependent (TD) Table ........................................................................... 167
Drucker Prager........................................................................................................ 168
User-Defined Constitutive Model (2D Only) ................................................................. 168
State Variable Initialization.................................................................................. 169
Graphical User Interface (GUI)............................................................................. 170
Input File Format ............................................................................................... 170
Tecplot Output................................................................................................... 172
Dynamic Link Library Compilation......................................................................... 172
User-Defined Material Rate Formulation Example.................................................... 173
User-Defined Material Total Formulation Example ................................................... 179
User-Defined Yield Surface Constitutive Model ............................................................. 186
Linear Kinematic/Isotropic UDYS Model ................................................................. 187
Solution Algorithms ............................................................................................ 187
Implementation ................................................................................................ 188
Material Parameters ........................................................................................... 190
Yield Surface Constitutive Model Setup.................................................................. 191
User-Defined Yield Surface Temperature Dependent Table ....................................... 193
Importing and Exporting Material Files........................................................................ 195
2D Simulation Options
General Options ...................................................................................................... 197
Simulation Mode ................................................................................................ 198
Chip Breakage ................................................................................................... 198
Residual Stress Analysis...................................................................................... 199
Steady State Analysis ......................................................................................... 199
Simulation Constraint ......................................................................................... 200
VI
Maximum Number of Nodes .................................................................................200
Meshing Options ......................................................................................................200
Minimum/Maximum Element Size .........................................................................201
Determining Minimum Element Size ......................................................................202
Mesh Refinement Factor ......................................................................................203
Mesh Coarsening Factor ......................................................................................204
Depth of Mesh Refinement for Residual Stress Analysis............................................205
Results Options........................................................................................................205
Number of Output Frames ...................................................................................205
Define Output Window ........................................................................................206
Additional Outputs ..............................................................................................206
Parallel Processing ...................................................................................................207
3D Simulation Options
General Options .......................................................................................................211
Simulation Mode.................................................................................................212
Residual Stress Analysis ......................................................................................212
Steady State Analysis .........................................................................................213
Meshing Options ......................................................................................................213
Results Options........................................................................................................216
Parallel Processing ...................................................................................................217
2D Parametric Study
Simulation Management
Saving Simulation Files .............................................................................................221
Saving Batch Files ..............................................................................................221
Job Monitor .............................................................................................................222
Runtime Error Codes ...........................................................................................224
License Monitor........................................................................................................226
Flexible Licensing .....................................................................................................229
Submitting a Single Simulation.............................................................................229
Submitting a Batch Job .......................................................................................230
Stopping and Restarting Jobs.....................................................................................232
Stopping a Job ...................................................................................................232
Restarting a Single Simulation..............................................................................232
Restarting a Batch Job ........................................................................................232
Opening Current Zone in Tecplot ..........................................................................233
Support/Archive Files Feature ....................................................................................233
Converting to Binary Files .........................................................................................234
VII
Results Analysis: Tecplot
Starting and Stopping Tecplot ................................................................................... 236
AdvantEdge Results Files .......................................................................................... 236
Contour Files ..................................................................................................... 236
Force Files ........................................................................................................ 236
Contour Plots .......................................................................................................... 236
Contour Variables .............................................................................................. 237
Contour Zone Style ............................................................................................ 237
Zone Selection................................................................................................... 238
Contour Type .................................................................................................... 238
Contour Legend and Contour Levels...................................................................... 238
Mesh Plots .............................................................................................................. 238
Mesh Attributes ................................................................................................. 239
Vector Plots ............................................................................................................ 239
Vector Plot Attributes.......................................................................................... 239
XY Plots ................................................................................................................. 240
XY Plot Attributes ............................................................................................... 240
Curve Fitting ..................................................................................................... 240
Animation Plots ....................................................................................................... 241
AdvantEdge Quick Analysis.................................................................................. 241
Animate Menu ................................................................................................... 242
Creating AVI/RM Files ......................................................................................... 243
Zone Selection Tool ................................................................................................. 243
Printing Plots .......................................................................................................... 245
Printing to a File or Printer .................................................................................. 245
Print Format ...................................................................................................... 245
Extracting Data ....................................................................................................... 245
Probing for Values .............................................................................................. 245
Extracting Polylines ............................................................................................ 246
User-Defined Output Variables .................................................................................. 247
Residual Stress Volume Averaging (3D only) ............................................................... 248
Analyzing Tool Stresses and Temperature History at User-Specified Elements (2D only) .... 251
Selecting a Variable............................................................................................ 251
Results Utilities: Tecplot

AdvantEdge Quick Analysis ....................................................................................... 253
Contour Tab ...................................................................................................... 254
Time History Tab ............................................................................................... 257
File Menu .......................................................................................................... 259
View Menu ........................................................................................................ 261
VIII
Data Menu.........................................................................................................261
Tools Menu ........................................................................................................262
ANSYS Export of Steady State Data ......................................................................269
Other Tecplot Functionalities......................................................................................270
Style Linking......................................................................................................270
Value Blanking ...................................................................................................272
Time-History Information Export...........................................................................275
Focused Location with Model Pressure Coolant Display.............................................277
HPC Client
System Requirements...............................................................................................279
Prerequisites......................................................................................................279
Installation .............................................................................................................280
HPC Server Setup ....................................................................................................281
License Activation Filter .......................................................................................281
HPC Progress Services.........................................................................................282
License Installation .............................................................................................282
HPC Client GUI ........................................................................................................283
User Credentials .................................................................................................283
Application Configuration .....................................................................................284
Email Notification ...............................................................................................285
Job Tracking ......................................................................................................286
Job Queue .........................................................................................................286
Job Task............................................................................................................287
Job Progress ......................................................................................................288
Submitting Jobs to the HPC Client ..............................................................................290
Using the AdvantEdge GUI...................................................................................290
Using the HPC Client GUI.....................................................................................294
References
Rake Angle Guide.....................................................................................................297
ISO Standard Tool Designations .................................................................................298
AdvantEdge Mesh Error Code List ...............................................................................298
Common Types of Bad Geometry for STEP Imports.......................................................303
Spot/Tiny Faces .................................................................................................303
Zero Volume ......................................................................................................304
Multiple Volumes ................................................................................................304
Edges with Zero Length .......................................................................................305
Twisted Faces ....................................................................................................305
STEP File Case Studies and Troubleshooting ................................................................306
IX
|
Suspicious Geometry Causes Bad Visualization....................................................... 306

Free Entities ...................................................................................................... 307
STEP File Could Not be Opened ............................................................................ 307
Face Could Not Be Meshed .................................................................................. 309
General STEP File Manipulation & Export in CATIA .................................................. 311
Additional Resources .......................................................................................... 318
Wear Models: Estimating Material Constants Based On Experimental Data....................... 319
Temperature Dependent Constitutive Models: Relating Conductivity to Heat Transfer........ 320
Stress Update Formulations ...................................................................................... 323
Rate Formulation (Jaumann Rate) ........................................................................ 323
Total Formulation (Deformation Gradient) ............................................................. 324
3D Parallel Processing Considerations......................................................................... 328
Computer Configuration ...................................................................................... 330
BIOS Setting ..................................................................................................... 330
Hyperthreading.................................................................................................. 330
Memory Setting ................................................................................................. 331
Material Cross Reference Guide ................................................................................. 331
Material Composition ............................................................................................... 336
Material Properties................................................................................................... 339
X
INTRODUCTION
Congratulations on choosing Third Wave AdvantEdge! With AdvantEdge you will be able to make
more informed decisions regarding your machining process, which will lead to dramatically
improved tool performance and part quality.
AdvantEdge Benefits
AdvantEdge is a powerful tool for designing, setting up, improving and optimizing machining
processes. It enables users to determine machining parameters and tooling configurations that can
reduce cutting forces, temperatures, and part distortion, all off-line. This reduces the need for
online testing, which costs money and valuable production time. Direct benefits of AdvantEdge
include:
• Reduced expensive cutting tests

• Prolonged tool life and reduce tool breakage
• Improved tool geometries and chip control
• Faster machining processes
• More efficient productivity
• Reduced part distortion due to heat generation, cutting forces, residual stress, etc.
• Increased material removal rates
• Increased machine utilization
AdvantEdge Components
AdvantEdge has three main components contained in one software package:
I
1. The Si m u l a t i o n Se t u p interface allows users to set up the entire simulation, including
defining tool geometries, material conditions, and machining parameters
2. The A d v a n t Ed g e En g i n e performs all the calculations from the setup inputs
3. The R e su l t s V i e w e r enables users to extract the necessary simulation results, includ-
ing cutting forces, tool temperature, steady state results, etc.
AdvantEdge Features
AdvantEdge combines advanced finite element technology with a user-friendly graphic interface
geared specifically for metal cutting simulations.
• 2D Graphical User Interface (GUI)

Tooling Capabilities
• Standard cutting tool geometries with rake and clearance angles

• Full drawing capability to define custom tool geometries with chip breaker features
• Definition and resolution of cutting edge radius (sharpness)
• Custom tool rotation for tool holder compensation
• User-selectable material grades
• Sandvik chip breaker tool library
• User-defined tool coating layers, materials, and thickness
Machining Parameters
• Process type options:

 Turning
 Sawing
 Broaching
 Milling
 Drilling
II
 Tapping
 Grooving
 Boring
• Micro-machining capability for turning processes
• Ability to input machining parameters such as feed, speed, depth of cut, length of cut, radial
engagement, etc.
• Variable chip load cutting modeling for up and down milling options
• Burr simulation capabilities
• SI/English unit option
M ATERI ALS
• Ever-increasing library of experimentally and numerically validated material models for

workpieces and tools; models have been developed specifically to describe the material’s
behavior under cutting conditions
• Custom Materials input capability
• Mechanical material properties including:
 Elastic
 Strain Hardening
 Rate Sensitivity
 Thermal Softening; includes specific heat and conductivity
• Workpiece hardness variation capability
• User-Defined Constitutive Model (2D Only)
• User-Defined Yield Surface Constitutive Model
AN ALYSI S
• Fully-automatic adaptive remeshing of finite element mesh, resolving features such as

primary and secondary shear zones
• Coupled thermo-mechanical time integration
• Thermal conduction and inertia effects for both workpiece and tool
• Multi-body contact with friction and interface heat conduction
• Cutting edge radius (sharpness) resolution and effects
• Residual Stress Analysis
• Steady State Analysis
• Chip Breakage
• Tool wear capability
VI SUALI ZATI ON OF RESULTS
• Status of simulation
III
• Results can be viewed by user at any time during simulation
• Various plotting options:
 Mesh Plots
 Contour Plots
 Vector Plots
 XY Plots
 Animation Plots
• Automated analysis tools
• Graphical display of analysis outputs:
 Chip characterization
 Cutting and transverse tool forces
 Tool/workpiece temperatures and heat generation rates
 Plastic strain and strain rate
 Mises, pressure and maximum shear stresses
 Stress components
 Velocity components and magnitude
Minimum System Requirements
AdvantEdge 2D (minimum)
• 2.5 GHz quad core Intel/AMD or higher processor

• 4GB of RAM
• 4.0 GB of disk space for installation; extra space required for each project
• NVIDIA graphic card display
• Supported platforms: Windows XP 32-/64-bit, Windows 7 64-bit
• .NET Framework 4.0 (installed automatically)
AdvantEdge 3D (minimum)
• 3.0 GHz quad core Intel Xeon/AMD or higher processor

• 4GB of RAM
• Supported platforms: Windows XP 32-/64-bit, Windows 7 64-bit
• .NET Framework 4.0 (installed automatically)
IV
Parallel Computing (minimum)
• Single processor with multi-core configurations

• 8.0 GB of RAM
• Supported platforms: Windows XP 64-bit, Windows 7 64-bit
Supported Platforms
• Windows XP 64-bit
• Windows 7 64-bit
Installation
1. Save all unsaved files and quit all Windows programs
2.Insert disk into CD-ROM drive or download release version (provided by Third Wave Sys-
tems Support team)
3.Run the setup.exe that was downloaded
4.Follow directions as prompted
5.Restart Computer before using AdvantEdge
Regional Settings (International Customers Only)
AdvantEdge users outside of the United States do not need to change their regional settings to
United States. AdvantEdge will automatically handle any regional settings.
Keyboard Shortcuts
AdvantEdge Shortcuts
• Ctrl+N: New Project Window

• Ctrl+O: Open Project Window
• Ctrl+S: Save Project
• Ctrl+Q: Exit AdvantEdge
V
• Ctrl+up: Zoom In
• Ctrl+down: Zoom Out
• Ctrl+F12: Fit to Full Size
Tecplot Shortcuts
• Ctrl+f: Fit to Full Size

• o (when rollerball is selected): Changes the center of rotation
• Refer to the Tecplot manual for more shortcuts
VI
CHAPTER 1 — 2D GETTING STARTED
There are four main steps to setting up a job: choosing the process, the workpiece material (see
Workpiece Materials), the tool definition (see 2D Tool Setup), and the process parameters (see 2D
Process Setup). All activities are completed using the AdvantEdge 2D Graphical User Interface
(GUI).
1.1 — Start a New Project

Windows 2000/XP: Open the Third Wave Systems folder found within the Windows St a r t >
P r o g r a m s menu and select the Third Wave AdvantEdge application.
To begin a new project, select P r o j e ct > N e w . Input a project/job name and identify the process
to be modeled. Project/Job description is optional. Both the project/job name and description may
be changed at any time by selecting P r o j e ct > O p t i o n s.
N ot e : The term “job” refers to the simulation or modeling project running on the
computer.
1.2 — Identify the Process Type

Select the 2 D Si m u l a t i o n option within the New Project window to access the available 2D
process types: Turning (with Micro-Machining option), up and down Milling, Sawing, or Broaching.
The process type chosen during the job definition defines the subsequent menus for tool and
process parameters.
1
2 D Ge t t in g St a r t e d | I de n t ify t h e Pr oce ss Type
Fi g u r e 1 - 1 : N e w P r o j e ct w i n d o w
Turning
The following are important notes to keep in mind when setting up a turning simulation:
• Feed is measured in distance/revolution

• Depth of cut is measured in the Z direction (going into the computer screen), perpendicular
to the feed and direction of the speed
• The workpiece moves with a cutting or surface velocity while the tool is assumed stationary.
The magnitude of the velocity is the cutting speed.
• Rake and clearance angles are shown with their positive convention
M I CRO- M ACH I N I N G
The AdvantEdge micro-machining capability allows users to simulate machining feeds of less than
1 micron (4.0 E-5 inch). When using the micro-machining feature, there are a couple of guidelines
that should be followed:
• Both the tool and workpiece should be scaled proportionally to the simulation feed and speed
 2D Tool Setup
 2D Workpiece Setup
• Meshing Options should be changed proportionally with the feed and cutting edge radius. The
minimum element size should be smaller than the cutting edge radius or feed, whichever is
smaller.
• Be patient; micro-machining simulations take longer than regular turning simulations
• If there are problems with the simulation, create a support file and send to the Third Wave
Systems support team at support@thirdwavesys.com
2
N ot e : The micro-machining feature should only be run by advanced AdvantEdge users.
Milling
The following are important notes to keep in mind when setting up a milling simulation:
• Feed is measured in distance/revolution/tooth

• Axial depth of cut is measured in the Z direction (going into to computer screen),
perpendicular to the feed and direction of the speed
• The workpiece moves with a cutting or surface velocity, while the tool is assumed stationary.
Sawing
The following are important notes to keep in mind when setting up a sawing simulation:
• Feed is measured in distance/tooth

• Blade thickness is measured in the Z direction (going into to computer screen), perpendicular
Broaching
The following are important notes to keep in mind when setting up a broaching simulation:
• Feed is measured in distance/tooth

• Tooth thickness is measured in the Z direction (going into to computer screen), perpendicular
3
2 D Ge t t in g St a r t e d | 2 D Gr a ph ica l Use r I n t e r fa ce ( GUI )
1.3 — 2D Graphical User Interface (GUI)

When setting up a simulation, the AdvantEdge graphical user interface (GUI) automatically displays
a visual representation of two machining components: the workpiece and cutting tool. This initial
screen will appear blank until the user creates a new project (see Start a New Project) or opens an
existing project. The GUI will reflect the defined tool configuration with default parameters for the
new project and user defined parameters for the existing project.
The GUI includes a top menu bar, informational panel with project parameters, and a display panel
showing coordinates for the position of the pointer in relation to the workpiece. Within the display
panel, the gold object represents the cutting tool, while the grey rectangular object represents the
workpiece to be machined.
Fi g u r e 1 - 2 : A d v a n t Ed g e 2 D Gr a p h i ca l U se r I n t e r f a ce
1.4 — Select Units

Decide the system of units to be used for the simulation by selecting P r o j e ct > O p t i o n s. By
default, AdvantEdge displays in SI units (International System of Units).
4
2 D Ge t t in g St a r t e d | Se t Pr e fe r e n ce s
Fi g u r e 1 - 3 : P r o j e ct O p t i o n s w i n d o w
1.5 — Set Preferences

The Set Preferences window in AdvantEdge allows users to establish processing preferences for all
future simulations. To open the Set Preferences window, select P r e f e r e n ce s > Se t
P r e f e r e n ce s.
Batch Processing
To run batch files from the GUI, activate the R u n Ba t ch Fi l e s f r o m GU I radio button within the
Batch Processing tab of the Set Preferences window.
N ot e : This option is only available for Windows users. Linux users will have to run the
batch files by double-clicking on the batch file.
Fi g u r e 1 - 4 : Ba t ch P r o ce ssi n g t a b o f Se t P r e f e r e n ce s w i n d o w
5
Default Folder
Users can set the default folder from which to start all future AdvantEdge sessions. This folder
location must be established within the Default Folder tab of the Set Preferences window.
Fi g u r e 1 - 5 : D e f a u l t Fo l d e r t a b o f Se t P r e f e r e n ce s w i n d o w
N ot e : Once the default folder is set, AdvantEdge will remember this folder when a new
session of AdvantEdge is started. For the current session, however, AdvantEdge will
continue to apply the most recently used folder. To apply the default folder settings
immediately, save the current project, exit AdvantEdge, and then start a new
session.
Metadata
To submit a job to the HPC Client, access the Metadata tab within the Set Preferences window and
browse to the XML template file designed to store project details. This XML file data will display a
custom defined table in the 2D Graphical User Interface (GUI) for user inputs.
Fi g u r e 1 - 6 : M e t a d a t a t a b o f Se t P r e f e r e n ce s w i n d o w
6
CHAPTER 2 — 3D GETTING STARTED
There are four main steps to setting up a job: choosing the process, the workpiece material (see
Workpiece Materials), the tool definition (see 3D Tool Setup), and the process parameters (see 3D
Process Setup). All activities are completed using the AdvantEdge 3D Graphical User Interface
(GUI).
2.1 — Start a New Project

Windows 2000/XP: Open the Third Wave Systems folder found within the Windows St a r t >
P r o g r a m s menu and select the Third Wave AdvantEdge application.
To begin a new project, select P r o j e ct > N e w . Input a project/job name and identify the process
to be modeled. Project/Job description is optional. Both the project/job name and description may
be changed at any time by selecting P r o j e ct > O p t i o n s.
N ot e : The term “job” refers to the simulation or modeling project running on the
computer.
2.2 — Identify the Process Type

Select the 3 D Si m u l a t i o n option within the New Project window to access the available 3D
process types: Turning, Milling, Drilling, Tapping, Grooving, Boring, or Orbital Drilling. Within each
of these processes are sub-operations; for example, turning processes include Oblique and Nose
Turning, and OD and Face Turning options.
7
Fi g u r e 2 - 1 : N e w P r o j e ct w i n d o w
Users can also simulate both solid and indexable tools for certain operations. The chart below lists
all sub-operations and applicable tool types. Some of the more unfamiliar terms are described in
the following sections.
8
Fi g u r e 2 - 2 : A d v a n t Ed g e 3 D su p p o r t e d p r o ce sse s
Turning
To Identify the Process Type to simulate, the following should be noted for turning processes:
• O b l i q u e T u r n i n g — Turning simulated without consideration of tool nose radius. Equivalent

to pipe turning.
• N o se T u r n i n g — Turning simulated with consideration of tool nose radius. Will exactly
mimic real life standard turning processes for large diameter workpieces.
• O D T u r n i n g — Turning simulated with consideration of tool nose radius, mimicking real life
standard turning processes for workpieces of any diameter
Milling
To Identify the Process Type to simulate, the following should be noted for milling processes:
• Si d e Cu t t i n g — Peripheral milling, not taking into account end of cutter
9
• Co r n e r Cu t t i n g — End/ball end milling, taking into account end of cutter

• R a m p M i l l i n g — Milling with vertical and horizontal feeds
• P l u n g e M i l l i n g — Milling with vertical velocity only. Basically is drilling with an end mill
tool.
After choosing the type of milling process to run, users will also need to specify whether they want
to run an up, down, 5-Axis Milling down, or Constant Chip Load Milling simulation. The availability of
each process is outlined below.
Ta ble 2 .1 : M illin g Pr oce ss M ode lin g Ava ila bilit y in Adva n t Edge 3 D
M illin g Ope r a t ion 5 - Ax is Con st a n t

Up D ow n
a n d Tool Type D ow n Ch ip Loa d
Side Cutting
Solid X X X
Indexable X X X
Stacked X X
Corner Cutting
Solid X X X
Indexable X X X X
Stacked X X
5 - AXI S M I LLI N G
For 5-axis milling, which is supported for Side Cutting and Corner Cutting, the tool is tilted/aligned
based on information provided by the user. Within the 5-axis milling Process Parameters window,
users may specify angles about the X and Y axes through which the tool should be rotated; or
indicate the vector along which the tool axis must be aligned.
CON STAN T CH I P LOAD M I LLI N G
For constant chip load milling, which is supported for Corner Cutting with an indexable tool (see
Indexable Tool for All Other Process Types), AdvantEdge will simulate a 3D nose turning simulation
based on maximum chip load calculations from the input milling parameters. Users must input
actual parameters for a milling operation into the user interface and AdvantEdge will run a
simulation to calculate forces at the point of maximum chip load.
N ot e : Constant chip load milling is not recommended if temperatures need to be found,

as AdvantEdge will not be simulating a transient process. However, it is highly
recommended for users looking to find the maximum forces and stresses in a
milling operation, as it will cut simulation time down significantly.
10
Drilling
To Identify the Process Type to simulate as drilling, the user will be prompted to select between
entrance, starting depth, and exit drilling processes.
• En t r a n ce p r o ce sse s simulate a drill entering a non-predrilled surface. In this model, the

surface is perpendicular to the drill feed direction. Slanted or curved surfaces are not mod-
eled.
• St a r t i n g d e p t h p r o ce sse s can be used when Steady State Analysis information is
needed. In this model, the workpiece is prepped so that fully-engaged cutting can happen
from the start of the process, avoiding the simulation of unnecessary entry stage informa-
tion. Besides a prompt for starting depth information, this process is the same as the
entrance process.
• Ex i t p r o ce sse s prompt the user to provide the number of rotations to exit. The tool posi-
tion is then automatically calculated.
Orbital Drilling
In an orbital drilling process, a cutting tool rotates around its own axis and simultaneously about a
center axis which is off-set from the axis of the cutting tool. The tool rotation is always clockwise,
but the user can define the orbital rotation to be counterclockwise to simulate down milling or
clockwise to simulate up milling.
Fi g u r e 2 - 3 : O r b i t a l d r i l l i n g t o o l a n d o r b i t a l r o t a t i o n f o r co u n t e r cl o ck w i se a n d cl o ck w i se
si m u l a t i o n s. R e d r e p r e se n t s r e g i o n t o b e cu t b y t h e t o o l .
2.3 — 3D Graphical User Interface (GUI)

The AdvantEdge graphical user interface (GUI) displays a visual representation of the Workpiece-
Tool Display. When the application first starts, the initial screen will appear blank. Once the user
has chosen to Identify the Process Type or open an existing project, the GUI will reflect the defined
tool configuration. When a new project is created, the tool configuration displays default settings.
To save time, the GUI will not automatically reflect any changes made to geometry or process
parameters. To display changes, click the R e g e n e r a t e T o o l / W o r k p i e ce button within the
AdvantEdge toolbar.
11
The display panel shows the cutting tool in gold and the workpiece in grey. To help the user set up
a simulation, the GUI also displays relevant process parameters for that specific process. In nose
turning, for example, tool feed, depth of cut, and workpiece motion are displayed.
Fi g u r e 2 - 4 : A d v a n t Ed g e 3 D Gr a p h i ca l U se r I n t e r f a ce
The AdvantEdge GUI includes a variety of viewing features. The following icons are part of a
viewing menu located directly to the left of the main GUI screen:
Fi t — fits the tool/workpiece into the view
Z o o m W i n d o w — zooms to a window the user creates by clicking left mouse button and
dragging
D y n a m i c Z o o m — zooms in or out using left mouse button and moving left or right with
mouse
D y n a m i c P a n — pans by holding the left mouse button
Fr o n t V i e w — rotates tool/workpiece to front view
T o p V i e w — rotates tool/workpiece to top view
Le f t V i e w — rotates tool/workpiece to left view
Ba ck V i e w — rotates tool/workpiece to back view
R i g h t V i e w — rotates tool/workpiece to right view
Bo t t o m V i e w — rotates tool/workpiece to bottom view
12
I so V i e w — rotates tool/workpiece to isometric view
W i r e f r a m e — displays tool/workpiece in wireframe form
So l i d — displays tool/workpiece in solid form
Gr i d — turns grid on/off
Gr i d R e f i n e — sets the grid size
R e g e n e r a t e T o o l / W o r k p i e ce — updates the GUI view
In addition to these icon functions, the user can r o t a t e the 3D view by holding the left mouse
button. P a n n i n g can be done by holding the right mouse button. The user can z o o m in or out by
holding the mouse wheel down and moving the mouse left or right.
Workpiece-Tool Display
The Workpiece-Tool Display submenu of the 3D Graphical User Interface (GUI) allows users working
with 3D simulations to view the tool, the workpiece, or the tool and workpiece together. This option
is especially useful when a STEP File Import includes both the tool and workpiece, as it allows the
user to verify relative position and orientation. Using this feature to help guarantee the setup is
correct before simulation occurs is strongly recommended. To use this feature, select V i e w >
W o r k p i e ce - T o o l D i sp l a y .
13
Fi g u r e 2 - 5 : W o r k p i e ce - T o o l D i sp l a y su b m e n u
Fi g u r e 2 - 6 : T o o l o n l y d i sp l a y
Fi g u r e 2 - 7 : W o r k p i e ce o n l y d i sp l a y
14
3 D Ge t t in g St a r t e d | Se le ct Un it s
Fi g u r e 2 - 8 : T o o l - W o r k p i e ce d i sp l a y
2.4 — Select Units

Decide the system of units to be used for the simulation by selecting P r o j e ct > O p t i o n s. By
default, AdvantEdge displays in SI units (International System of Units).
Fi g u r e 2 - 9 : P r o j e ct O p t i o n s w i n d o w
2.5 — Set Preferences

The Set Preferences section of AdvantEdge allows users to establish processing preferences for all
future simulations. To open the Set Preferences window, select P r e f e r e n ce s > Se t
P r e f e r e n ce s.
15
Batch Processing
To run batch files from the GUI, activate the R u n Ba t ch Fi l e s f r o m GU I radio button from the
Batch Processing tab of the Set Preferences window.
N ot e : This option is only available for Windows users. Linux users should set the
appropriate permissions for the batch file to run on a Linux machine.
Fi g u r e 2 - 1 0 : Ba t ch P r o ce ssi n g t a b o f Se t P r e f e r e n ce s w i n d o w
Default Folder
Users can set the default folder from which to start all future AdvantEdge sessions. This folder
location must be established within the Default Folder tab of the Set Preferences window.
N ot e : Once the default folder is set, AdvantEdge will remember this folder when a new
session of AdvantEdge is started. For the current session, however, AdvantEdge will
continue to apply the most recently used folder. To apply the default folder settings
immediately, save the current project, exit AdvantEdge, and then start a new
session.
Fi g u r e 2 - 1 1 : D e f a u l t Fo l d e r t a b o f Se t P r e f e r e n ce s w i n d o w
16
CHAPTER 3 — 2D TOOL SETUP
3.1 — Standard Tools

A standard tool is a cross section of a standard flat face turning insert, a milling tooth, a sawing
tooth, or a broaching tooth. To adjust standard tool parameters, select T o o l > Cr e a t e / Ed i t
St a n d a r d T o o l to open the Tool Parameters window. Within this window, users can define cutter
diameter (milling processes only), cutting edge radius, rake angle, and relief angle.
Fi g u r e 3 - 1 : D o w n M i l l i n g T o o l P a r a m e t e r s w i n d o w
The A d v a n ce d O p t i o n s button of the Tool Parameters window opens the Advanced Options win-
dow. Within this window the user can define relief length, rake length, maximum element size, min-
imum element size, and mesh grading. The relief length and rake length define the size of the tool.
The other parameters define the tool mesh, and are explained in detail in the Standard Oblique Tool
Modeler window section.
17
2 D Tool Se t u p | Cu st om a n d I m por t e d Tools
Fi g u r e 3 - 2 : T u r n i n g T o o l A d v a n ce d O p t i o n s w i n d o w
3.2 — Custom and Imported Tools

To allow for more customization, AdvantEdge users have the option to Create a Custom Tool,
Import a Custom Tool, or select a DXF Tool Import that contains the cross sections of tools. A user
might create or import the cross section when they wish to model the characteristics of a chip
breaker. Once the tool is created, the Custom Tool Editor can be used to make modifications such as
boundary condition adjustments.
N ot e : The Custom Tool Editor also has the capability to zoom in or out from the current
view. This is done by either dragging a box with the left mouse button, or by using
te “+” and “-” keys. The U n d o button at the top of the Custom Tool Editor will undo
the last step performed. The R e se t button will adjust the Custom Tool Editor
window to display the entire tool.
Create a Custom Tool
To create a new custom tool, select T o o l > Cr e a t e Cu st o m T o o l . The Custom Tool Editor will
open, providing a grid to assist in defining the vertices. In this window the user will add points in a
counter-clockwise fashion to define the cross section geometry of the tool. Using the cursor, which
appears as a “+”, select points along the grid to define the polygon. Precise placement is not neces-
sary, as each vertex position can be changed later.
18
Fi g u r e 3 - 3 : Cu st o m T o o l Ed i t o r w i n d o w
N ot e : The coordinates of each vertex are specified within the local coordinate system with
the origin (0,0) located at the tool tip point. The tool tip will always be located at
the origin. For example, the custom tool shown above was drawn in the positive X-
axis direction to allow for a negative rake angle geometry. To finish creating the
tool, click on the origin (0,0) and the polygon will close. When the polygon is
closed, the indicator in the lower right corner will switch from “Open” to “Close.”
N ot e : Tools must be drawn in a clockwise fashion or meshing problems may be

encountered during simulations, causing less accurate results. For more, see
AdvantEdge Mesh Error Code List.
Import a Custom Tool
To import a previously-created custom tool or a custom tool within the Sandvik tool library, select
T o o l > I m p o r t T o o l , then choose between three available options:
• T o o l s — A directory of custom tools created by the user. Tools have *.twt extensions.
• Sa n d v i k — A directory of standard chip breakers for specified Sandvik inserts. Tools have
*.twt extensions.
• D X F — A file with a *.dxf extension that defines the cross section geometry.
19
Custom Tool Editor
Parameters for Custom and Imported Tools can be modified by utilizing the Custom Tool Editor. To
open the Custom Tool Editor, select T o o l > Ed i t Cu st o m T o o l .
ED I T CUSTOM TOOL GEOM ETRY
Within the Custom Tool Editor window, vertices can be moved using two different methods:
1. Click the Ed i t button and place the cursor near the desired vertex. When the cursor turns
into a hand, left click on the vertex, move the mouse to the desired position, and left click
again.
2. Click the Ed i t button and place the cursor near the vertex until the cursor appears as a
hand. Right click on the vertex to open the Vertex Parameters window. Type the appropri-
ate coordinate values and the vertex will move to this position.
Fi g u r e 3 - 4 : V e r t e x P a r a m e t e r s w i n d o w
Within the Vertex Parameters window, the user can also alter the boundary conditions of the vertex.
ED I T VERTEX/ TOOL TI P RAD I US
To edit the tool tip radius or vertex radius within the Custom Tool Editor window, move the cursor
near the desired vertex. When the cursor becomes a hand icon, right click. The Vertex Parameters
window will open. Enter the value for the radius within the input box labeled Radius in the upper
left-hand corner, then click O K.
N ot e : For a custom tool, the default tool tip radius is 15 microns. Other vertices within the
tool geometry have a default radius of zero.
20
2 D Tool Se t u p | D yn a m ic Tool I n pu t s
AD D / D ELETE TOOL VERTEX
To add a tool vertex, click the A d d button located at the top of the Custom Tool Editor window.
Click on the segment of the tool where the new vertex will be located. An additional vertex will
appear within the window and the user can move the vertex to its desired location.
To delete a tool vertex, click the D e l e t e button located at the top of the Custom Tool Editor, then
click on the vertex to be removed. The shape of the tool will adjust accordingly.
SET BOUN D ARY CON D I TI ON S
Before the simulation can begin, boundary conditions for the custom tool must be defined. Normally
with both custom and standard tools, the right- and top-most sides of the tool are fixed in the X and
Y directions. However, with custom tools the user has the option to define the boundary condition
fixed in the X direction, Y direction, or both X and Y directions.
N ot e : A fixed boundary condition should NOT be applied to a side that will incur contact.
N ot e : Tools must contain a minimum of one vertex each fixed in the X and Y directions.
To set boundary conditions, click the A d d or Ed i t button within the Custom Tool Editor window,
then right click on the appropriate vertex to be constrained. The Vertex Parameters window will
open, allowing users to enter necessary information into the appropriate boundary condition sec-
tion.
Once a boundary condition has been defined, a new line will display in the Custom Tool Editor, run-
ning from the vertex point just edited to the next clockwise vertex point. The color of this line iden-
tifies what boundary condition was applied:
• Bl a ck — constrained in the X and Y directions

• Gr e y — constrained in the Y direction only
• Li g h t Gr e y — constrained in the X direction only
A newly-created custom tool can be saved under a name other than the project name by selecting
T o o l > Sa v e T o o l A s. This allows the user to store all custom tools in one folder with names that
describe the chip breaker or insert type. In the future, the user can import these custom tools into
other project setups.
3.3 — Dynamic Tool Inputs

AdvantEdge is able to add a prescribed boundary condition on the tool, including Elliptical Tool
Vibration and Vibration Assisted Machining, Stiffness and Damping, and Vertical Velocity. All options
are accessible by selecting T o o l > D y n a m i c T o o l M o d e l i n g .
21
Fi g u r e 3 - 5 : D y n a m i c T o o l M o d e l i n g su b m e n u
Elliptical Tool Vibration and Vibration Assisted Machining
The vibrating assisted machining (VAM) and elliptical tool vibration feature can be used to increase
tool life, improve chip breakage, or decrease forces. AdvantEdge allows the user to simulate this
motion and analyze its results. The user can simulate one-dimensional vibrations by prescribing
vibration in the X or Y direction, or simulate two-dimensional vibrations by prescribing vibration in
both directions. The user can generate elliptical tool motion by utilizing the Initial Angle option. To
open the Vibrating Tool window, select T o o l > D y n a m i c T o o l M o d e l i n g > V i b r a t e T o o l
M ode l.
Fi g u r e 3 - 6 : V i b r a t i n g T o o l w i n d o w w i t h t y p i ca l se t u p . Si n ce a m p l i t u d e s a r e p o si t i v e a n d t h e
i n i t i a l a n g l e f o r X v i b r a t i o n i s 9 0 d e g r e e s l e ss t h a n t h e i n i t i a l a n g l e f o r Y v i b r a t i o n , m o t i o n
w i l l b e cl o ck w i se .
To create a one-dimensional VAM, check either the X or Y checkbox within the Vibrating Tool win-
dow. The tool will vibrate at the input frequency and in the selected direction, starting from the
neutral position (at the feed depth and zero length of cut). Tool motion can be reversed by entering
a negative amplitude.
22
To create a two-dimensional VAM, check both the X and Y checkboxes within the Vibrating Tool win-
dow and enter the amplitude, frequency, and initial angle for the desired motion. The tool will start
in the neutral position and move along an elliptical path as shown below. Depending on the sign of
the initial angle difference and vibration amplitudes, the motion generated may be clockwise (CW)
or counterclockwise (CCW). The equation in the Vibrating Tool window can be used to verify that
the tool will be rotating the correct way.
To model elliptical motion, it is recommended that the user enter equivalent frequencies for X and Y,
+/-90 degrees for the X initial angle, and 0 or 180 degrees for the Y initial angle.
Fi g u r e 3 - 7 : R e co m m e n d e d p a r a m e t e r s f o r e l l i p t i ca l m o t i o n
If the user intends the cut to be centered about the nominal feed depth (entered in the 2D Process
Setup window), the Y initial angle should always be set to zero or a multiple of 180.
N ot e : It is NOT recommended to prescribe amplitudes greater than the feed.
Fi g u r e 3 - 8 : I f a n y v a l u e o t h e r t h a n 0 ( o r a n y m u l t i p l e o f 1 8 0 ) i s e n t e r e d f o r t h e Y i n i t i a l
a n g l e , t h e e l l i p t i ca l m o t i o n w i l l n o t b e ce n t e r e d a r o u n d t h e n o m i n a l f e e d v a l u e
The Vibrating Tool window will apply input boundary conditions to all previously rigid tool boundary
conditions, including ones prescribed in the custom tool (see Set Boundary Conditions).
23
Stiffness and Damping
The effect of 2D tool holders and boring bars can be simulated using the Stiffness and Damping
window. This will more accurately describe the action of the tool for more force plots and overall
simulations. To open the Stiffness and Damping window, select T o o l > D y n a m i c T o o l M o d e l i n g
> St i f f n e ss/ D a m p i n g .
Fi g u r e 3 - 9 : St i f f n e ss a n d D a m p i n g w i n d o w
Select the directions that should have a prescribed stiffness and input the values. If a direction is
not specified, AdvantEdge will assume the tool is rigid. Negative values are not allowed to be input.
For 3D analyses, this feature is available only for Turning Tools and Grooving Tools. It is not sup-
ported when using a rotating workpiece.
Vertical Velocity
The Vertical Velocity window allows users to apply a velocity perpendicular to the cutting speed.
This is particularly useful for horizontal composite layers. To open the Vertical Velocity window,
select T o o l > D y n a m i c T o o l M o d e l i n g > V e r t i ca l ( y ) V e l o ci t y. Check the V e r t i ca l V e l o c-
i t y checkbox and enter the desired velocity.
• Composite Workpieces: Turning/Broaching/Sawing
For information on standard cutting speeds, see 2D Process Setup.
Fi g u r e 3 - 1 0 : V e r t i ca l V e l o ci t y w i n d o w
24
2 D Tool Se t u p | Tool M a t e r ia l
3.4 — Tool Material
Standard Tool Materials
To define a standard Tool Material, open the Tool Material window by selecting T o o l > T o o l M a t e -
r i a l . Select the material to use.
N ot e : Items that appear grey within the Tool Material window indicate the tool grade
category.
Fi g u r e 3 - 1 1 : T o o l M a t e r i a l w i n d o w
Tool Coatings
To define a tool coating, open the Tool Coating window by selecting T o o l > Co a t i n g . Users must
define the number of coating layers before defining the type of material. Select the material type
(standard or custom) and input the layer thickness. Layer 1 is considered the inner-most layer and
each additional layer falls outside the previous. Up to three layers may be entered.
The coatings in AdvantEdge are not defined explicitly with their own unique mesh. Instead, the
coating layer properties are applied within the existing tool mesh starting at the surface.
25
Fi g u r e 3 - 1 2 : T o o l Co a t i n g P a r a m e t e r s w i n d o w
Custom Tool Materials
In AdvantEdge, users have the ability to create a custom Tool Material. Tool materials are assumed
to be elastic; therefore, the associated constitutive model requires commonly-available mechanical
and thermal properties.
To create a custom tool material, select T o o l > T o o l M a t e r i a l and activate the Cu st o m radio
button. Indicate the Constitutive Model to be utilized by selecting Cu st o m M a t e r i a l s > Co n st i -
t u t i v e M o d e l and clicking on the appropriate model. When the model is selected, a check mark
will appear next its name within the menu. Finally, open the Tool Material window by selecting Cu s-
t o m M a t e r i a l s > T o o l M a t e r i a l . Parameters necessary to describe the User-Defined constitu-
tive model will appear; the user must enter appropriate values for these parameters to correctly
define their custom material. These parameters will be used by AdvantEdge when performing calcu-
lations.
For more, see Custom Materials.
26
2 D Tool Se t u p | Tool W e a r
3.5 — Tool Wear

AdvantEdge offers tool wear modeling capabilities allowing the user to either select standard or
custom tool wear models. To open the Tool Wear Model window, select T o o l > W e a r M o d e l , then
select the Tool Wear Model checkbox to activate the tool wear capability.
Fi g u r e 3 - 1 3 : T o o l W e a r M o d e l w i n d o w
Users can select from four different tool wear models by clicking the corresponding radio buttons:
Standard Wear Model, Custom Wear Model, Usui’s Wear Model, or User-Defined Wear Model.
All tool wear model options allow users to define the following parameters or accept the default val-
ues:
1. T o t a l T o o l W e a r T i m e — total time in minutes for which the tool cutting wear will be
predicted
2. W e a r T i m e I n cr e m e n t — time step of each wear iteration used by AdvantEdge to
update the worn tool geometry
3. M a x W e a r I n cr e m e n t — nodal distance set up as a tolerance for the mesh tool to
adapt
4. Sm o o t h i n g A n g l e — tolerance on the internal angle within the mesh. The mesh uses
this value during adaption.
N ot e : Users should select a length of cut (LOC) that allows the simulation to reach steady
state, which may require the length of cut to be at least 15 times the feed. To
ensure that the correct length of cut is chosen, the user should run a test case that
allows the tool to make one complete pass. The length of cut can be defined by
selecting P r o ce ss > P r o ce ss P a r a m e t e r s.
Standard Wear Model
Two pre-defined Tool Wear models are available within AdvantEdge. The workpiece materials for
these models are AISI 52100 and D3 steel. The corresponding tool material is Cubic-Boron-Nitride
for both models.
27
To select a standard wear model, activate the St a n d a r d radio button within the Tool Wear Model
window. Then click the M a t e r i a l / P a r a m e t e r button to open the Workpiece-Tool Material Pair
window. Within the Workpiece-Tool Material Pair window, select the workpiece-tool material combi-
nation desired. When the pairing is chosen, it will be highlighted in blue.
Fi g u r e 3 - 1 4 : W o r k p i e ce - T o o l M a t e r i a l P a i r w i n d o w
Custom Wear Model
The custom wear model allows the user to calculate Tool Wear based on the cutting velocity (cutting
speed in SMM). To utilize this model, select the Cu st o m radio button within the Tool Wear Model
window followed by the M a t e r i a l / P a r a m e t e r button. The Custom Wear Material window will
open, within which the user can define constants K and Alpha, which are both dimensionless.
Fi g u r e 3 - 1 5 : Cu st o m W e a r M o d e l w i n d o w
The following equation shows how these constants relate to the tool wear rate:
28

w· = K  e  – --------------------------  V
 T + 273.15
K and  are material constants, w· represents the wear rate (the volume loss per unit area per unit
time), T represents the steady state temperature of the tool with a given amount of wear, and V is
the cutting velocity.
N ot e : STEP File Case Studies and Troubleshooting provides an example of how to

estimate material constants.
Usui’s Wear Model
The Usui’s Wear Model is similar to the Custom Wear Model, except nodal velocities are taken into
consideration when calculating the Tool Wear rate, and the constant K has units (1/Pa). To apply
this model, activate the U su i ’ s M o d e l radio button within the Tool Wear Model window and click
the M a t e r i a l / P a r a m e t e r button.
Fi g u r e 3 - 1 6 : U su i ’ s M o d e l w i n d o w
Within the Usui’s Model window the user can define the material constants K and  . These con-
stants relate to the wear rate by the following equation:

w· = K  e  – --------------------------  p  v
 T + 273.15
K and  are material constants, w· represents the wear model (volume loss per unit area per unit
time), T represents the steady state temperature of the tool with a given amount of wear, v is the
sliding velocity, and p is the pressure.
29
N ot e : STEP File Case Studies and Troubleshooting provides an example of how to

estimate material constants.
User-Defined Wear Model
The user-defined wear model allows users to define custom Tool Wear models by utilizing the FOR-
TRAN dynamic library. The user-defined wear model classifies the wear rate (volume loss per unit
area per unit time) as a function of temperature ( T ), sliding velocity ( v ), and pressure ( p ). This is
shown in the following equation: w· = f  T  v p . When using this model, the provided steps should be
completed:
1. Implement an equation for wear rate within the FORTRAN subroutine and save it as User-
WearModel.f
N ot e : A sample UserWearModel.f exists within the advanteng bin.
2. Compile the subroutine to a *.dll file by typing the following command into the Intel FOR-
TRAN COMPILER:
>ifort /DLL /libs:static /threads UserWearModel.f
3. If necessary, rename the *.dll file as UserWearModel.dll
4. Replace any existing UserWearModel.dll file located in the advanteng bin with the new
UserWearModel.dll
5. Create a simulation
6. Select T o o l > W e a r M o d e l
7. Check the T o o l W e a r M o d e l checkbox within the Tool Wear Model window
8. Activate the U se r D e f i n e d radio button and click the M a t e r i a l P a r a m e t e r s button
9. Click the P a r a m e t e r T a b l e button to open the Defined Parameter-Tool Wear window
Fi g u r e 3 - 1 7 : D e f i n e d P a r a m e t e r - T o o l W e a r w i n d o w
30
2 D Tool Se t u p | Tool M e sh Vie w e r
10. Input values for the variables specified within the subroutine
11. Add comments that help clarify each variable (these comments are used for bookkeeping
purposes only)
12. Click O K in all three windows
13. Save the file (see Saving Simulation Files)
14. Submit the simulation (see Flexible Licensing is an upgrade available for AdvantEdge. It
provides the user more flexibility by breaking the license up by core count instead of exe-
cution. With this capability users are able to get greater through-put in order to quickly
solve problems. For more information or to purchase this upgrade, contact sales@third-
wavesys.com.)
3.6 — Tool Mesh Viewer

The Tool Mesh Viewer allows users to preview tool mesh before running 2D simulations. It also
allows for Selective Element Plotting for tracking group-wise averaged time history plots for various
stress components, such as principal stress or Von Mises stress. To open the Tool Mesh Viewer,
select T o o l > T o o l M e sh V i e w e r.
Fi g u r e 3 - 1 8 : T o o l M e sh V i e w e r
When utilizing the Tool Mesh Viewer, the following options are available:
• Cl e a r A l l — deselects all elements
31
2 D Tool Se t u p | Tool M e sh Vie w e r
• Z o o m — available when the By El e m e n t button is selected. To zoom, use the mouse to

drag a selection box over the desired area.
• P a n — allows the user to move the tool and workpiece up, down, right, or left. To pan, use
the arrow keys on the keyboard.
• R e se t V i e w — resets the view to its original size. Any zoom or pan performed before this
option will be undone.
Selective Element Plotting
Time history plots can be created in the Tool Mesh Viewer by designating elements of interest
either:
• By El e m e n t — selecting individual elements. Choose either the Se l e ct El e m e n t or

U n se l e ct El e m e n t button and use the mouse to click particular elements of interest. When
an element is selected, it will appear green.
Fi g u r e 3 - 1 9 : T o o l M e sh V i e w e r w i n d o w h i g h l i g h t i n g sa m p l e e l e m e n t se l e ct i o n s
• By R e g i o n — selecting multiple points at once. Click either the Se l e ct El e m e n t or

U n se l e ct El e m e n t button and use the mouse to drag a selection box over the desired
region. All selected elements will become green. To alternate between regions, use the
dropdown menu provided at the upper left corner of the Tool Mesh Viewer window.
N ot e : The workpiece mesh cannot be selected or deselected.
32
CHAPTER 4 — 3D TOOL SETUP
4.1 — Turning Tools

AdvantEdge 3D options for turning processes include Oblique Turning Tool, Nose, OD, and Face
Turning Tools. Since the same basic tool is used in nose, OD, and facing operations, the same
modeling strategies apply.
Oblique Turning Tool
STAN D ARD OBLI QUE TOOL
Standard oblique Turning Tools are defined as flat rake faced tools. To define a standard tool go to
T o o l > Cr e a t e / Ed i t St a n d a r d T o o l . Enter the tool geometry information in the window.
Fi g u r e 4 - 1 : St a n d a r d O b l i q u e T o o l M o d e l e r w i n d o w
33
3 D Tool Se t u p | Tu r n in g Tools
Nose, OD, and Face Turning Tools
Nose, OD, and face Turning Tools all use turning inserts where nose radii are modeled; however, the
tool orientation differs. To select a standard tool for any of the three turning processes listed above,
select T o o l > Cr e a t e / Ed i t St a n d a r d T o o l .
The ISO tool designation, tool holder rake angles, and tool edge radius can be entered into the ISO
Tool Parameters window. For help on geometry inputs, click the H e l p button. For more, see ISO
Standard Tool Designations.
Fi g u r e 4 - 2 : I SO T o o l M o d e l e r w i n d o w f o r n o se , O D , a n d f a ce t u r n i n g t o o l s
Wiper Inserts (Nose Turning Only)
Wiper inserts may be utilized to improve surface roughness, efficiency, tool life, or chip control for
nose Turning Tools. AdvantEdge models such effects by applying a wiper geometry to the trailing
edge of the tool. Wiper insert definitions are input within the ISO Tool Modeler window by selecting
T o o l > Cr e a t e / Ed i t St a n d a r d T o o l . To activate this option, select the W i p e r Ge o m e t r y
checkbox and specify a desired wiper radius and offset.
Fi g u r e 4 - 3 : I SO T o o l M o d e l e r w i n d o w w i t h W i p e r Ge o m e t r y f e a t u r e a ct i v a t e d
34
3 D Tool Se t u p | M illin g Tools
4.2 — Milling Tools

When running a 3D milling simulation, users will find that there are a variety of tool setups
depending on the process being modeled. Side (peripheral) milling simulations are unique in that
they do not take into account the tool nose. All other types of milling (corner, face, ramp, plunge,
and pocket) will account for the tool nose.
Side Cutting Solid End Milling Tool
When using side cutting solid end Milling Tools, users are able to input cutter diameter, core
diameter, number of flutes, radial rake angle, radial relief angle, edge radius, flute radius, width of
land, and tool length. Click the A d v a n ce d O p t i o n s button to specify tool mesh parameters.
Fi g u r e 4 - 4 : So l i d M i l l w i n d o w
Side Cutting Indexable Milling Tool
When using side cutting indexable Milling Tools, users are able to input cutter diameter, number of
teeth, radial rake angle, axial rake angle, lead angle, relief angle, edge radius, tool width, tool
height, and tool length. Click the A d v a n ce d O p t i o n s button to specify tool mesh parameters.
35
Fi g u r e 4 - 5 : I n d e x a b l e Si d e Cu t t i n g T o o l M o d e l e r w i n d o w
Solid Milling Tool for All Other Process Types
Corner cutting, ramp milling, plunge milling and pocket milling processes all use the same tool
parameters window as solid Milling Tools. Face milling is not an option with solid tools.
For end mills (used for ramp, plunge, corner, and pocket milling), users can input cutter diameter,
core diameter, number of flutes, radial rake angle, helix angle, radial relief angle, axial relief angle,
corner radius, edge radius, flute radius, width of land, and tool length. Click the A d v a n ce d
O p t i o n s button to specify tool mesh parameters.
36
Fi g u r e 4 - 6 : So l i d En d M i l l w i n d o w
For ball end mills (corner cutting only), the tool does not have a corner radius; instead, a
hemispherical shape is attached to the top of the tool shank. The cutting edge on each tooth
extends over this hemisphere up to the center of the tool. Users should input ball radius, core
radius, number of flutes (fixed between 2 and 4), radial rake angle, helix angle, radial relief angle,
edge radius, flute radius, width of land, tool length, and taper angle (defines the end mill as having
a conical shape). Click the A d v a n ce d O p t i o n s button to specify tool mesh parameters.
Fi g u r e 4 - 7 : Ba l l En d M i l l w i n d o w
37
Indexable Tool for All Other Process Types
Corner cutting, face milling, ramp milling, plunge milling, and pocket milling processes all use the
same tool parameters window when creating indexable Milling Tools.
Within the Indexable Tool Setup window, users can select insert parameters and input cutter
diameter, number of teeth, radial rake angle, axial rake angle, lead angle, edge radius, and tool
width. Clicking the A d v a n ce d O p t i o n s button allows users to specify tool mesh parameters.
Fi g u r e 4 - 8 : I n d e x a b l e Co r n e r Cu t t i n g M o d e l e r w i n d o w
Stacked Milling Tools
Users have the option of running stacked Milling Tools with side cutting, corner cutting, or ramp
milling. This will simulate an indexable mill with multiple inserts per tooth. For stacked milling
setups, two tabs are present within the Tool Setup window: Insert Geometry and Stack Parameters.
I N SERT GEOM ETRY
Within the Insert Geometry tab of the Stacked Insert Tool window, users can input insert length,
width, height, front relief angle, side relief angle, top angle, cutting edge radius, side angle radius,
and corner radius.
38
Fi g u r e 4 - 9 : I n se r t Ge o m e t r y t a b o f St a ck e d I n se r t T o o l w i n d o w
STACK PARAM ETERS
Within the Stack Parameters tab of the Stacked Insert Tool window, users can input number of
flutes, number of inserts per flute, height increment, stack helix angle, and cutter diameter. Click
the A d v a n ce d O p t i o n s button to specify tool mesh parameters.
Fi g u r e 4 - 1 0 : St a ck P a r a m e t e r s t a b o f St a ck e d I n se r t T o o l w i n d o w
Runout
Users can prescribe a runout for Milling Tools in the Cartesian or Polar coordinates to model the tool
runout. This feature can be used to study the effect of tool runout on cutting. To access runout
options, select T o o l > Cr e a t e / Ed i t St a n d a r d T o o l (for standard tools) or T o o l > I m p o r t
T o o l > ST EP T o o l Fi l e (for imported tools) and click the A d v a n ce d O p t i o n s button. The
runout feature is not available for custom tools.
39
Fi g u r e 4 - 1 1 : R u n o u t P a r a m e t e r s t a b o f A d v a n ce d O p t i o n s w i n d o w
Information entered into the Runout Parameters tab of the Advanced Options window will be used
to shift the tool appropriately. The distance between the tool center and the rotation center is R (for
Cartesian inputs). The maximum allowed runout R is 100 μm. Large runout may cause AdvantEdge
to abort due to excessive initial penetration between the tool and workpiece.
Runout that occurs in some milling processes may become non-negligible. In order to capture this
occurrence, check the R u n o u t O N / O FF checkbox at the top of the Runout Parameters tab. Once
a user has selected to include runout in the analysis, a coordinate system must be designated. Two
choices are possible:
• Ca r t e si a n Co o r d i n a t e Sy st e m — Enter the runout in the X and Y directions. The maxi-

mum allowable runout radius is 100 microns.
• P o l a r Co o r d i n a t e Sy st e m — Enter the runout radius and angle. The maximum allowable
runout radius is 100 microns.
N ot e : Runout parameters should only be adjusted by experienced AdvantEdge users, as

the parameters can significantly affect mesh quality and performance.
Differential Pitch
Differential pitch Milling Tools contain unevenly spaced inserts, and have different harmonics than
cutters with evenly spaced inserts. Differential pitch cutters are often used to reduce vibrations. To
access differential pitch options, select T o o l > Cr e a t e / Ed i t St a n d a r d T o o l (for standard tools)
or T o o l > I m p o r t T o o l > ST EP T o o l Fi l e (for imported tools) and click the A d v a n ce d
O p t i o n s button. The differential pitch feature is not available for custom tools.
40
3 D Tool Se t u p | D r illin g Tools
Fi g u r e 4 - 1 2 : D i f f e r e n t i a l P i t ch t a b o f A d v a n ce d O p t i o n s w i n d o w
In AdvantEdge, inserts are referred to as teeth. For every tooth present in the assembly, an angle is
used to determine its location in relation to tooth one. Thet a2 is the angle between tooth one and
tooth two, Thet a3 is the angle between tooth one and tooth three, and so on. Initially, inserts will
be evenly spaced.
When the differential pitch feature is activated, the maximum number of inserts is 6. AdvantEdge
requires a minimum angle of 15 degrees between inserts. This minimum angle does not prevent
the inserts from overlapping each other if the tool diameter is small, or the inserts are big.
N ot e : Differential pitch cannot be used if workpiece Boolean is selected.
4.3 — Drilling Tools
Solid Drilling Tool
A solid drilling process can be simulated by creating a parametric model of a 2-flute twist drill
(Standard Drill), Split Point Drill, or Double Angle Point Drill. To open the Drilling Parameters
window, select T o o l > Cr e a t e / Ed i t St a n d a r d T o o l .
STAN D ARD D RI LL
Within the Standard Drill tab of the Drilling window, users can input drill diameter, body diameter
clearance, helix angle, web thickness, flute radius, flute length, and edge radius.
41
Select the D e si g n P a r a m e t e r s option from the dropdown menu to input point, clearance, and
chisel edge angles.
Fi g u r e 4 - 1 3 : St a n d a r d D r i l l t a b o f D r i l l i n g w i n d o w
• Cl e a r a n ce A n g l e (nominal relief angle) increases from the periphery to the axis of the
drill. It is conventionally specified at the outer corner of the cutting edge. The clearance angle
keeps the drill flank from rubbing against the workpiece.
Select the Gr i n d P a r a m e t e r s option from the dropdown menu to input semi-cone angle, drill
point position, tilt angle, and skew distance.
42
Fi g u r e 4 - 1 4 : Gr i n d P a r a m e t e r s o p t i o n se l e ct e d f r o m w i t h i n St a n d a r d D r i l l t a b o f D r i l l i n g
w in dow
SPLI T POI N T D RI LL
A split point drill can be indicated within the Split Point Drill tab of the Drilling window. Information
needed for this feature includes web thickness after splitting, splitting angle, notch angle, and
notch wheel angle. To activate this feature, check the Se l e ct Sp l i t P o i n t D r i l l checkbox.
Fi g u r e 4 - 1 5 : Sp l i t P o i n t D r i l l t a b o f D r i l l i n g w i n d o w
43
The six parameters that define the split point drill are based on the National Aerospace Standards
(NAS); however, the naming convention deviates slightly. Please refer to Table 4.1 below for
clarification.
Ta ble 4 .1 : N a m in g Con ve n t ion Con ve r sion fr om Adva n t Edge t o N AS
Adva n t Edge N a m in g Con ve n t ion N AS N a m in g Con ve n t ion
Web thickness after splitting Web thickness after notching
Splitting angle Secondary cutting edge angle
Notch angle Notch angle
Notch wheel angle Splitting wheel face angle
Notch rake angle Notch rake angle
AdvantEdge does not capture non-essential geometry, and it also assumes the following:
• The drill tip has a constant relief angle, whereas an actual drill has curved relief (relief angle
changes along the cutting edge)
• The body diameter clearance is modeled as a notch behind the relief face on the outer diam-
eter of the drill. In reality the body diameter clearance is a curved transition behind the cut-
ting edge.
D OUBLE AN GLE POI N T D RI LL
A double angle point drill can also be indicated within the Double Angle Point Drill tab of the Drilling
Parameters window. Information needed for this feature includes secondary drill diameter and
secondary drill point angle. To activate this feature, check the Se l e ct D o u b l e A n g l e P o i n t D r i l l
checkbox.
44
3 D Tool Se t u p | Or bit a l D r illin g Tools
Fi g u r e 4 - 1 6 : D o u b l e A n g l e P o i n t D r i l l t a b o f D r i l l i n g w i n d o w
Indexable Drilling Tool
Parametric tool definition is currently not available for Indexable Drilling. Please import this tool as
a STEP file.
4.4 — Orbital Drilling Tools

To define a standard tool for orbital drilling, select T o o l > Cr e a t e / Ed i t St a n d a r d T o o l .
When defining a standard orbital drill, a variety of parameters are required: cutter diameter, core
diameter, number of flutes, radial rake angle, helix angle, radial relief angle, axial relief angle,
corner radius, edge radius, flute radius, width of land, tool length. To specify tool mesh parameters,
click the A d v a n ce d O p t i o n s button.
45
3 D Tool Se t u p | Gr oovin g Tools
Fi g u r e 4 - 1 7 : O r b i t a l D r i l l i n g w i n d o w
4.5 — Grooving Tools

For grooving simulations, users can select straight-line or rotating workpieces. When the diameter
is less than 20 mm, a rotating workpiece option should be selected. This selection will yield more
accurate results for smaller diameters because the radius of the workpiece plays a more significant
role in affecting forces.
Standard Grooving Tool
To create standard Grooving Tools, open the Tool Parameters window and select T o o l > Cr e a t e /
Ed i t St a n d a r d T o o l . When using a standard, “square” grooving tool, users will be prompted to
input the tool length, width, height, front relief angle, side relief angle, side angle, top angle, taper
angle, cutting edge radius, side edge radius, and corner radius.
46
3 D Tool Se t u p | Bor in g Tools
Fi g u r e 4 - 1 8 : Sq u a r e Gr o o v i n g T o o l w i n d o w
Cone Tool
To create cone-shaped Grooving Tools, open the Tool Parameters window and select T o o l >
Cr e a t e / Ed i t St a n d a r d T o o l . When using a cone-shaped grooving tool, users will be prompted
to input the cutting edge radius, cone angle, rake angle, and tool height.
Fi g u r e 4 - 1 9 : Co n e T o o l P a r a m e t e r s w i n d o w
4.6 — Boring Tools

A boring tool is very similar to an Oblique Turning Tool, the only difference being that the user can
specify multiple inserts.
47
3 D Tool Se t u p | Ta ppin g Tools
To open the Standard Boring Tool Parameters window, select T o o l > Cr e a t e / Ed i t St a n d a r d

T o o l . For standard boring tools, users will be prompted to input side rake angle, back rake angle,
lead angle, edge radius, tool width, tool diameter, and number of teeth.
Fi g u r e 4 - 2 0 : I SO T o o l M o d e l e r w i n d o w f o r st a n d a r d b o r i n g t o o l s
4.7 — Tapping Tools

Due to the complicated nature of tapping tools, the only option for defining tapping tool parameters
in AdvantEdge is to import a previously-defined STEP file. Both right- and left-hand tapping tools
can be imported.
For complete information on importing STEP files into AdvantEdge, see 3D External File Imports.
4.8 — Custom Tools

To allow for more customization, AdvantEdge users have the option to create a custom tool for
select 3D processes. Custom tools can be made for Custom Oblique Turning Tools, Custom Nose,
OD, and Face Turning Tools, or Custom Boring & Indexable Milling Tools. Once the tool is created,
the Custom Tool Editor can be used to make modifications or edit a custom tool already defined by
selecting T o o l > Ed i t Cu st o m T o o l .
Custom Tool Editor
To create new Custom Tools, select Tool > Cr e a t e Cu st om Tool. The Custom Tool Editor window
will open, providing a grid to assist in defining the vertices. In this window the user will add points
in a counter-clockwise fashion to define the cross section geometry of the tool. Using the cursor,
48
3 D Tool Se t u p | Cu st om Tools
which appears as a “+”, select points along the grid to define the polygon. Precise placement is not
necessary, as each vertex position can be changed later.
Fi g u r e 4 - 2 1 : Cu st o m T o o l Ed i t o r w i n d o w
The coordinates of each vertex are specified within the local coordinate system with the origin (0,0)
located at the tool tip point. The tool tip will always be located at the origin. For example, the
custom tool shown above was drawn in the positive X-axis direction to allow for negative rake angle
geometry. To finish creating the tool, click on the origin (0,0) and the polygon will close. When the
polygon is closed, the indicator in the lower right corner will switch from “Open” to “Close.”
Tools must be drawn in a clockwise fashion or meshing problems may be encountered during
simulations, causing less accurate results. The Custom Tool Editor also has the capability to zoom
in or out from the current view. This is done by either dragging a box with the left mouse button, or
by using the “+” and “-” keys. The Undo button at the top of the Custom Tool Editor will undo the
last step performed. The Reset button will adjust the Custom Tool Editor window to display the
entire tool.
A newly-created custom tool can be saved under a name other than the project name by selecting
T o o l > Sa v e T o o l A s. This allows the user to store all custom tools in one folder with names that
describe the chip breaker or insert type. In the future, the user can import these custom tools into
other project setups.
49
Options available in the Custom Tool Editor vary depending on the process that is selected.
Depending on the process, the user can define the width, lead angle, side rake angle, back rake
angle, relief angle, and the edge radius.
ED I T CUSTOM TOOL GEOM ETRY
Within the Custom Tool Editor window, vertices can be moved using two different methods:
1. Click the Ed i t button and place the cursor near the desired vertex. When the cursor turns
into a hand, left click on the vertex, move the mouse to the desired position, and left
click again.
2. Click the Ed i t button and place the cursor near the vertex until the cursor appears as a
hand. Right click on the vertex to open the Vertex Parameters window. Type the
appropriate coordinate values and the vertex will move to this position. This option allows
for more precision because the Vertex Parameters window can be used to specify exact
vertex parameters.
Fi g u r e 4 - 2 2 : V e r t e x P a r a m e t e r s w i n d o w
Within the Vertex Parameters window, the user can also alter the Boundary Conditions of the
vertex.
ED I T VERTEX/ TOOL TI P RAD I US
To edit the tool tip radius or vertex radius within the Custom Tool Editor, move the cursor near the
desired vertex. When the cursor becomes a hand icon, right click. The Vertex Parameters window
will open. Enter the value for the radius in the upper left-hand corner, then click O K.
N ot e : For a custom tool, the default tool tip radius is 15 microns. Other vertices within the
tool geometry have a default radius of zero.
50
BOUN D ARY CON D I TI ON S
Before the simulation can begin, boundary conditions for the custom tool must be defined. Normally
with both custom and standard tools, the right- and top-most sides of the tool are fixed in all
directions. However, with custom tools the user has the option to define the boundary condition
fixed in the X direction, Y direction, Z direction, or any combination of the three.
N ot e : A fixed boundary condition should NOT be applied to a side that will incur contact.
N ot e : Tools must contain a minimum of one vertex each fixed in the X, Y, and
Z directions.
To set boundary conditions, click the A d d or Ed i t button within the Custom Tool Editor, then right
click on the appropriate vertex to be constrained. The Vertex Parameters window will open, allowing
users to enter necessary information into the appropriate boundary condition section.
Once a boundary condition has been defined, a new line will display in the Custom Tool Editor,
running from the vertex point just edited to the next clockwise vertex point. The color of this line
identifies what boundary condition was applied:
• Bl a ck — constrained in the X, Y, and Z directions

• Gr e y — constrained in any two directions
• Li g h t Gr e y — constrained in only one direction
Tool width must be determined after boundary conditions have been prescribed. Because of
material deformation, the tool must be wider than the workpiece. In general, it is recommended
that the width of tool should be at least 3 times the width of the workpiece.
AD D / D ELETE TOOL VERTEX
To add a tool vertex, click the A d d button located at the top of the Custom Tool Editor. Click on the
segment of the tool where the new vertex will be located. An additional vertex will appear within
the window and the user can move the vertex to its desired location.
To delete a tool vertex, click the D e l e t e button located at the top of the Custom Tool Editor, then
click on the vertex to be removed. The shape of the tool will adjust accordingly.
AD VAN CED OPTI ON S
Within the Custom Tool Editor, the user can define the meshing parameters for the tool. Changing
these parameters can affect results, so only experienced users should change these parameters. To
change the meshing parameters, click the A d v a n ce d O p t i o n s button. Mesh gradation in the
initial tool mesh creates finer elements near the tool tip vicinity and relatively larger elements away
from the tool tip. Because of refined mesh at the cutting edge, there will be better contact and
more accurate results at the tool tip without increasing the computational time significantly.
51
Fi g u r e 4 - 2 3 : A d v a n ce d O p t i o n s w i n d o w
• M a x i m u m T o o l El e m e n t Si z e — the element size in the region far from the tip vicinity
region of the tool
• M i n i m u m T o o l El e m e n t Si z e — the element size at the tip vicinity of the tool
• M e sh Gr a d i n g ( G) — determines the nature of transition from fine elements near the cut-
ting edge to coarse elements away from the cutting edge. Decreasing this parameter will
increase meshing success and simulation stability, but will also increase element count and
simulation time.
 G = 0.1 (Min. Value) — Very slow transition results in overall refined mesh
 G = 1.0 (Max. Value) — Fast transition results in coarse mesh
Fi g u r e 4 - 2 4 : M e sh g r a d a t i o n
• Cu r v a t u r e Sa f e t y ( C) — determines the accuracy with which curved geometric features in

the model are captured in the mesh. If the user has several complex features, this value can
be increased to more accurately capture the shape in the mesh; however, this will increase
element count and simulation time.
 C = 0.2 (Min. Value) — Curves are not captured very accurately. Results in coarse mesh.
 C = 5.0 (Max. Value) — Curves are captured accurately. Results in fine mesh.
52
• Se g m e n t s P e r Ed g e ( S) — determines the density of nodes on unit length of any edge in

the model. Can be used for complex geometries that consist of many complex surfaces to
increase meshing success and model accuracy; however, increasing this parameter will
increase element count and simulation time.
 S = 0.2 (Min. Value) — Results in very coarse mesh
 S = 5.0 (Max. Value) — Results in very fine mesh
• M i n i m u m Ed g e Le n g t h — minimum allowed edge length for any element in the mesh.
Geometric features smaller than this value will not be captured properly. Suggested mini-
mum edge length is anywhere between 10 and 40 microns. After initial surface mesh, edges
below this number may be eliminated by changing the size of surrounding elements. If the
minimum edge length is near the minimum element size, it is possible that elements on the
cutting edge will be changed, causing a non-uniform mesh. Using this parameter can elimi-
nate small elements in the tool and decrease simulation time.
• N u m b e r o f Ed g e Fa ce t s — sets how many elements make up the cutting edge. This value
should be set to a range of 2–4; however, the default settings are highly recommended.
Custom Oblique Turning Tools
A custom oblique tool can be used to create specialized geometries, such as a T-Land or chip
breaker geometry. For oblique turning, orthogonal cutting is the default; however, there is an
option for oblique cutting when first setting up the simulation (see Oblique and Nose Turning). The
amount of obliqueness can be changed within the Back Rake Angle area located in the bottom right
corner of the Custom Tool Editor.
53
Fi g u r e 4 - 2 5 : Cu st o m T o o l Ed i t o r w i n d o w f o r o b l i q u e t u r n i n g
Custom Nose, OD, and Face Turning Tools
The setup for custom nose, OD, and face turning tools is the same as Custom Oblique Turning
Tools; however, the tool definition is different. When drawing the tool, users will be creating the top
view of the cutting surface. The radius defined at (0,0) will be the tool nose radius, not the edge
radius.
Like other custom tools, mechanical constraints must be entered. Tool holder angles, including the
back rack angle, can be entered in the same way as for Custom Oblique Turning Tools; for
additional help on inputting rake angles, see the Rake Angle Guide. Edge radius, relief angle and
rake angle (called Side Rake Angle in AdvantEdge) options are listed under the nose turning
simulation.
N ot e : Users MUST define the nose turning tool using exactly 4 points. AdvantEdge does
not support more or less than 4 points for tool geometry definitions.
54
Fi g u r e 4 - 2 6 : Cu st o m T o o l Ed i t o r w i n d o w f o r n o se , O D , a n d f a ce t u r n i n g . P i ct u r e d i s a 9 0 -
d e g r e e i n se r t w i t h a 0 . 8 m m n o se r a d i u s.
In addition to a standard flat rake faced tool, users can model a custom cutting edge for turning.
This assumes a constant geometry perpendicular to the cutting edge and nose radius. After
entering relief angles, tool width and rake angles in the Custom Tool Editor window, activate the
Cu st o m Cu t t i n g Ed g e radio button. The Custom Cutting Edge Editor window will open. The
default displays a cross section of a flat rake faced tool.
55
Fi g u r e 4 - 2 7 : Cu st o m Cu t t i n g Ed g e Ed i t o r w i n d o w
N ot e : The vertices in the middle of the rake face, as well as other default vertices, are
fixed and cannot be moved or edited. However, users can add and move other ver-
tices between these points and the cutting edge. Users can also move the cutting
edge to create a T-Land chamfer or a chip breaker.
Fi g u r e 4 - 2 8 : Cu st o m T - l a n d ( l e f t ) a n d ch i p b r e a k e r ( r i g h t ) cu t t i n g e d g e s cr e a t e d w i t h i n t h e
Cu st o m Cu t t i n g Ed g e Ed i t o r w i n d o w
56
Custom Boring & Indexable Milling Tools
Custom boring and indexable milling tools can be created in the same ways as Custom Nose, OD,
and Face Turning Tools; however, angle orientations will differ.
Fi g u r e 4 - 2 9 : Cu st o m T o o l Ed i t o r w i n d o w f o r si d e cu t t i n g
57
3 D Tool Se t u p | St iffn e ss a n d D a m pin g
Fi g u r e 4 - 3 0 : Cu st o m T o o l Ed i t o r f o r b o r i n g
4.9 — Stiffness and Damping

AdvantEdge is able to add a prescribed stiffness/dampening condition to tools by selecting T o o l >
D y n a m i c T o o l . Using the Stiffness and Dampening window, the effects of the tool holders and
boring bars can be simulated. This will more accurately describe the action of the tool and better
predict forces.
58
Fi g u r e 4 - 3 1 : St i f f n e ss a n d D a m p i n g w i n d o w
Select the directions that should have a prescribed stiffness and input the values. If a direction is
not specified, AdvantEdge will assume the tool is rigid. Negative values are not acceptable inputs.
N ot e : The dynamic stiffness/dampening tool input feature is only available for Grooving
and Turning operations without rotating workpieces.
4.10 — Tool Material

The AdvantEdge 3D tool material features are identical for all 2D and 3D simulations, with the
exception of the 3D Cutter Body Material. For complete information on all other tool materials, see
Custom Tool Materials.
Cutter Body Material
Cutter body modeling is available for 3D indexable Milling and Drilling processes using imported
STEP tools (for more, see Importing STEP Tool Files). The cutter body feature allows users to
specify cutting inserts and tool cutter body solids for an imported STEP assembly file.
To open the Cutter Body Material window, select T o o l s > Cu t t e r Bo d y M a t e r i a l . Within this
window, users can choose Tool Material from three different high-speed steels, or choose a custom
material.
59
Fi g u r e 4 - 3 2 : Cu t t e r Bo d y M a t e r i a l w i n d o w
4.11 — Tool Wear

The AdvantEdge 3D tool wear features are available for Turning Tools, Grooving Tools, and Constant
Chip Load Milling simulations. Features are identical to the 2D Tool Wear features.
4.12 — Tool Deflection

The tool deflection feature incorporates the influence of tool deflection due to cutting forces. To
open the tool deflection feature, select T o o l > D y n a m i c T o o l > T o o l D e f l e ct i o n . This feature
is only available for Milling Tools and Drilling Tools.
Fi g u r e 4 - 3 3 : T o o l D e f l e ct i o n O p t i o n s w i n d o w
60
3 D Tool Se t u p | Tool D e fle ct ion
AdvantEdge models the portion of the tool between the tool holder and the cutting portion, which
includes the shank and part of the flute, as a beam. The beam is fixed on top and linked with the
top surface of the cutting portion.
Depending on the geometry of the tool, AdvantEdge can model one or two beams. Beam types are
distinguished by their cross sectional area and the moment of inertia. The most convenient tool
deflection method is to model the shank as one beam. To use this method, check Be a m 1 and
input the length and diameter of the shank. The moment of inertia and cross sectional area assume
a cylindrical shape and are determined accordingly.
If the tool section differs significantly, the user should model two types of beams. This allows the
user to input the moment of inertia and cross sectional area data for more complex geometries. If
Beam 2 is checked, Beam 1 must also be checked. The beam parameters cannot be zero.
Fi g u r e 4 - 3 4 : T o o l D e f l e ct i o n O p t i o n s w i n d o w sh o w i n g sa m p l e se t u p
For solid Milling Tools, the shank material is the same as the Tool Material. For indexable milling
tools, the user can select a shank material by clicking the Sh a n k M a t e r i a l button at the bottom
of the Tool Deflection Options window. If the material needed is not available through the Shank
Material window, activate the Cu st o m radio button and input the material data by selecting
Cu st o m M a t e r i a l s > Sh a n k M a t e r i a l .
Fi g u r e 4 - 3 5 : Sh a n k M a t e r i a l w i n d o w
61
CHAPTER 5 — 2D WORKPIECE SETUP
5.1 — Standard Workpieces: Turning/Sawing/

Broaching
To define standard workpiece parameters for 2D turning, sawing, and broaching simulations, select
W o r k p i e ce > Cr e a t e / Ed i t St a n d a r d W o r k p i e ce .
Input the workpiece length and height. In order to minimize boundary effects, the workpiece height
should be at least five times the feed. Initial Stress can also be input within this window.
N ot e : For normal force analysis, the workpiece length and the length of cut (defined in
the Turning Process Parameters window) must be long enough for the simulation to
reach steady state.
Fi g u r e 5 - 1 : T u r n i n g W o r k p i e ce w i n d o w
63
2 D W or k pie ce Se t u p | St a n da r d W or k pie ce s: Up a n d D ow n M illin g
Initial Stress
The user can also prescribe an initial stress within the Standard Workpieces: Turning/Sawing/
Broaching window. Using this feature may more accurately simulate the forces within a workpiece
with residual stress from heat-treating or previous machining. The file containing initial stress
information has a *.tws extension and its format is shown below:
% Initial Stress input, depth, sigxx,sigzz,sigyz

25.d-6,10.d6,10.d6,0.d0
50.d-6,10.d6,10.d6,0.d0
100.d-6,10.d6,10.d6,0.d0
125.d-6,10.d6,10.d6,0.d0
150.d-6,10.d6,10.d6,0.d0
200.d-6,10.d6,10.d6,0.d0
250.d-6,10.d6,10.d6,0.d0
300.d-6,10.d6,10.d6,0.d0
350.d-6,10.d6,10.d6,0.d0
500.d-6,10.d6,10.d6,0.d0
Initial stress file units are in meters [depth] and Pascals (N/m2) [stresses]. The depth of specified
stress must not be greater than the workpiece height. The number of lines in the file may range
from 1 to 2000.
To utilize this feature, check the I n i t i a l St r e ss checkbox within the Workpiece window and
browse to the desired file containing initial stress information.
N ot e : The initial stress file must be saved in the same directory as the simulation itself
(see Saving Simulation Files). If not, the simulation will not run properly.
5.2 — Standard Workpieces: Up and Down Milling

In up and down milling 2D simulations, the only input for standard workpieces is a workpiece width.
The workpiece length will be determined automatically by AdvantEdge, as milling produces a non-
uniform chip.
Initial stresses can be specified in the same manner as 2D turning, sawing, and broaching
simulations. For more, see Initial Stress.
64
2 D W or k pie ce Se t u p | W or k pie ce M a t e r ia ls
Fi g u r e 5 - 2 : U p M i l l i n g W o r k p i e ce w i n d o w
5.3 — Workpiece Materials

The workpiece material definition is an important part of the simulation setup and very important to
the user’s results. For example, aluminum will cut very differently than stainless steel; this
difference is witnessed not only in forces, but also in chip flow, thickness and temperature.
Standard Workpiece Materials
AdvantEdge has an ever-expanding library of standard materials that can be used to define
workpiece material, Tool Material, and Tool Coatings. These are all included in the software and
offer users a wide range of tool and workpiece materials. Standard material compositions and
properties are listed in a pop-up menu in the Workpiece Material window, and also detailed in the
Material Cross Reference Guide.
To define a standard workpiece material, select W o r k p i e ce > M a t e r i a l . The Workpiece Material

window will open, which contains a dropdown menu of regions around the world. Since countries
assign different names to the same materials, selecting the correct region allows users to more
easily identify the correct material. The Workpiece Material window also allows for material
selection from a dropdown menu, automatically displaying the corresponding material name. Once
the correct material has been selected, Brinell hardness can be edited by activating the V a r i a b l e
H a r d n e ss radio button and entering information in the input box. To view the ultimate tensile
strength, initial yield strength, hardness, and material composition, click the P r o p e r t i e s button.
N ot e : The Workpiece Material window is the same for 2D and 3D simulations.
65
2 D W or k pie ce Se t u p | Cu st om W or k pie ce s: Tu r n in g/ Br oa ch in g/ Sa w in g
Fi g u r e 5 - 3 : W o r k p i e ce M a t e r i a l w i n d o w
Custom Workpiece Materials
To define a custom workpiece material, select W o r k p i e ce > M a t e r i a l . Within the Workpiece

Material window, activate the Custom radio button and then close the window. Materials can then
be imported through the Custom Materials menu.
5.4 — Custom Workpieces: Turning/Broaching/Sawing

User-defined workpieces can be created in AdvantEdge and used to simulate variable chip loads,
interrupted cuts or heating of the workpiece ahead of the cutter. To open the Custom Workpiece
Editor window, select W o r k p i e ce > Cr e a t e Cu st o m W o r k p i e ce .
66
2 D W or k pie ce Se t u p | Com posit e W or k pie ce s: Tu r n in g/ Br oa ch in g/ Sa w in g
Fi g u r e 5 - 4 : Cu st o m W o r k p i e ce Ed i t o r w i n d o w
Creating a custom workpiece is very similar to creating a custom tool (see Custom and Imported
Tools for more information). When creating a custom workpiece, the following should be taken into
consideration:
• The workpiece needs to be fixed in both the X and Y direction in some respect
• Standard workpieces have the bottom boundary fixed in the X and Y
• Only Set Boundary Conditions where contact does not occur (for DXF tool imports, see
Boundary Conditions)
• Feed is measured from the top most point on the workpiece
• Avoid contact with sharp corners
• Temperatures can be prescribed on any length
5.5 — Composite Workpieces: Turning/Broaching/

Sawing
AdvantEdge allows users to utilize composite workpieces with up to 5 layers of material, each with
a prescribed thickness. This feature allows the user to simulate interactions between material
layers, such as an aluminum engine block with a cast iron liner. To establish a composite workpiece,
select W o r k p i e ce > Co m p o si t e W o r k p i e ce .
67
Fi g u r e 5 - 5 : Co m p o si t e W o r k p i e ce w i n d o w w i t h H o r i z o n t a l La y e r s o p t i o n se l e ct e d
Fi g u r e 5 - 6 : Co m p o si t e W o r k p i e ce w i n d o w w i t h V e r t i ca l La y e r s o p t i o n se l e ct e d
Input the height/length of the workpiece, then select the number of layers and input the material
and thickness for each layer. Users have the ability to select a custom material from the material
dropdown menu. If this is selected, access Cu st o m M a t e r i a l > Co n st i t u t i v e M o d e l to specify
the material model desired and Cu st o m M a t e r i a l > W o r k p i e ce M a t e r i a l > M a t e r i a l 1
(2,3,etc.) to define the custom material. This must be done for each custom material layer. Once
the material is imported using the Custom Material menu, AdvantEdge will create a *.twm file for
each layer.
68
N ot e : The boundary between composite layers is assumed to be frictionless.
Fi g u r e 5 - 7 : A d v a n t Ed g e GU I sh o w i n g co m p o si t e w o r k p i e ce se t u p w i t h v e r t i ca l l a y e r s
69
CHAPTER 6 — 3D WORKPIECE SETUP
All workpiece parameters windows are accessed through the Workpiece menu. Each 3D process has
a unique workpiece input window with customized graphics.
6.1 — Turning Workpieces
Oblique Turning Workpieces
When defining oblique Turning Workpieces, nose radius is not taken into account. Thus, the 3D
oblique turning workpiece is similar to 2D Standard Workpieces: Turning/Sawing/Broaching, with
the addition of a depth of cut parameter.
To keep simulation times to a minimum, users should make the workpiece height approximately
5 times the feed.
71
3 D W or k pie ce Se t u p | Tu r n in g W or k pie ce s
Fi g u r e 6 - 1 : T u r n i n g W o r k p i e ce w i n d o w f o r o b l i q u e t u r n i n g
For some turning and milling applications, the Pre-cut Boolean Workpiece feature can be used to
position the tool and “cut” the workpiece so the simulation is at full chip load from the start. This
saves on simulation time.
Fi g u r e 6 - 2 : O b l i q u e t u r n i n g w o r k p i e ce se t u p u t i l i z i n g P r e - cu t Bo o l e a n W o r k p i e ce f e a t u r e
Nose Turning Workpieces
To keep simulation times to a minimum, users should follow these guidelines when defining nose
Turning Workpieces:
• Workpiece height should be to approximately 5 times the feed

• Workpiece width should be about half the workpiece height
72
3 D W or k pie ce Se t u p | Tu r n in g W or k pie ce s
The Pre-cut Boolean Workpiece feature can be used to create an initial cut and initial stress can be
implemented in the workpiece. For more on initial stress parameters, see Initial Stress.
Fi g u r e 6 - 3 : T u r n i n g W o r k p i e ce w i n d o w f o r n o se t u r n i n g
OD and Face Turning Workpieces
When defining OD and face Turning Workpieces, users can simply input the workpiece diameter and
length. When assigning a workpiece length, it is recommended to calculate how far the tool will be
fed down the workpiece and add 1 mm. Workpieces with diameters larger than 20 mm should be
simulated with the nose turning module (see Oblique and Nose Turning), as anything larger than
20 mm will take significant time to simulate using the OD or face turning modules.
Fi g u r e 6 - 4 : O D T u r n i n g W o r k p i e ce w i n d o w
73
3 D W or k pie ce Se t u p | M illin g W or k pie ce s
6.2 — Milling Workpieces
Side Cutting Workpieces
Side cutting workpiece parameters are similar to Oblique Turning Workpieces, as the tool nose is
not taken into consideration in either process.
To determine a suitable workpiece width, the user should take into consideration the number of
passes to be made by the milling cutter teeth. It is recommended that the workpiece width be
about 5 times the feed. When assigning a workpiece length, it is recommended to multiply the
speed by the number of passes the tool will make and add some extra length.
N ot e : The workpeice for side milling will be positioned automatically. The center of the
workpeice thickness will be lined up with the center of the tool mesh geometry.
Imported tooling may need to be modified, such as removing the non-cutting shaft
in a solid endmill to avoid a meshing error.
Fi g u r e 6 - 5 : Si d e M i l l i n g W o r k p i e ce w i n d o w
Corner Cutting Workpieces
Parameters for corner cutting workpieces are similar to those of Nose Turning Workpieces. As with
nose turning workpieces, it is recommended that the workpiece height and width be about 5 times
the feed. The workpiece length should be large enough to allow for material to be removed for the
number of passes in the simulation.
74
Fi g u r e 6 - 6 : Co r n e r Cu t t i n g W o r k p i e ce w i n d o w
CON STAN T CH I P LOAD M I LLI N G W ORKPI ECE
Constant chip load milling is available only for corner cutting milling operations using indexable
tools. The process will be simulated as a nose turning operation, with the feed as the maximum
chip load from a milling operation. Workpiece parameters will look similar to a nose turning
simulation, and the workpiece length will be determined by the process parameters of the
simulation.
Fi g u r e 6 - 7 : Co r n e r M i l l i n g W o r k p i e ce w i n d o w se t u p f o r co n st a n t ch i p l o a d
75
Face Milling Workpieces
Face milling simulations operate like those utilizing Corner Cutting Workpieces, except that the tool
is lined up down the workpiece center line. In general, the workpiece height should be about
5 times the feed.
Fi g u r e 6 - 8 : Fa ce M i l l i n g W o r k p i e ce w i n d o w
Ramp Milling Workpieces
The ramp milling workpiece window requests the same input parameters as a Face Milling
Workpieces. When calculating workpiece height, users should add additional length to the depth
that the mill will reach at the end of the simulation.
Fi g u r e 6 - 9 : R a m p M i l l i n g W o r k p i e ce w i n d o w
76
Plunge Milling Workpieces
In a plunge milling simulation, the user should specify the workpiece height based on whether or
not the mill will cut all the way through the workpiece or stop at a certain depth.
Fi g u r e 6 - 1 0 : P l u n g e M i l l i n g W o r k p i e ce w i n d o w
Pocket Milling Workpieces
Pocket milling workpieces differ from the other 3D Milling Workpieces because the cut is more
complex. However, the standard workpiece window remains simple. The user is required to input
the workpiece width, height, and length.
Fi g u r e 6 - 1 1 : P o ck e t M i l l i n g W o r k p i e ce w i n d o w
77
3 D W or k pie ce Se t u p | D r illin g W or k pie ce s
6.3 — Drilling Workpieces
Standard Drilling Workpieces
Regardless of the Drilling simulation type (entrance, starting depth or exit drilling), the Standard
Workpiece Parameters window for all Drilling Workpieces will require only a workpiece length, width
and height. It is recommended to keep the workpiece width and length at 2 times the drill diameter,
so that edge effects are not significant.
The user should also consider the simulation type when inputting a workpiece height; for example,
with a starting depth simulation, the user may want the drill to be completely engaged in cutting
(drill point is completely within workpiece). The workpiece height would need to be changed
accordingly.
Fi g u r e 6 - 1 2 : D r i l l i n g W o r k p i e ce - St a r t i n g D e p t h w i n d o w
Drilling Workpieces with Pilot Holes
A feature specific to drilling and orbital drilling simulations is modeling a workpiece with a pilot hole.
To model a pilot hole, open the Drilling Pilot Hole Setup window by selecting W o r k p i e ce > P i l o t
H o l e . The top and bottom pilot hole diameters, as well as a pilot hole depth, must be specified. If
simulating a pilot hole with a uniform diameter, the top and bottom diameters should be the same.
An offset can also be specified for the drill; the maximum allowable offset varies.
78
3 D W or k pie ce Se t u p | D r illin g W or k pie ce s
Fi g u r e 6 - 1 3 : D r i l l i n g W o r k p i e ce w i t h a P i l o t H o l e w i n d o w
Composite Drilling Workpieces
Composite (“stack up”) drilling/orbital drilling operations are simulated by layering Workpiece
Materials on top of each other to allow for cross layer drilling. To open the Composite Workpiece
window, select W o r k p i e ce > Co m p o si t e W o r k p i e ce . Indicate the number of layers (up to 5)
and the thickness of each layer. The sides of the workpiece are fixed and the layer interface is linear
friction. The top and bottom of the workpiece are free, allowing for breakout to be simulated.
79
3 D W or k pie ce Se t u p | Gr oovin g W or k pie ce s
Fi g u r e 6 - 1 4 : Co m p o si t e W o r k p i e ce w i n d o w
Oblique Drilling Workpieces
To simulate entry angles for Drilling Workpieces, open the Oblique Entrance Setup window by
selecting W o r k p i e ce > O b l i q u e D r i l l i n g . Maximum angle is 45 degrees.
Fi g u r e 6 - 1 5 : O b l i q u e D r i l l i n g W o r k p i e ce w i n d o w
6.4 — Grooving Workpieces

Standard Grooving Tool (non-rotating) and Cone Tool simulations have the same workpiece inputs.
For these grooving simulations, the workpiece height should be 3-5 times the width of the grooving
80
3 D W or k pie ce Se t u p | Gr oovin g W or k pie ce s
channel, and the workpiece width should be 3-5 times the grooving depth. As with turning
simulations, the workpiece length should be longer than the length of cut, unless a burr is desired.
Fi g u r e 6 - 1 6 : Gr o o v i n g W o r k p i e ce w i n d o w
For a rotating workpiece grooving simulation, workpiece length and diameter inputs are required.
Users are advised to run non-rotating workpiece grooving simulation when modeling workpieces
with diameters greater than 20 mm.
Fi g u r e 6 - 1 7 : O D Gr o o v i n g W o r k p i e ce w i n d o w f o r r o t a t i n g w o r k p i e ce g r o o v i n g si m u l a t i o n s
81
3 D W or k pie ce Se t u p | Bor in g W or k pie ce s
6.5 — Boring Workpieces

Boring workpieces are created as cylinders with holes (inner diameters) where tools will cut. When
entering the workpiece length, it is recommended to calculate how far the tool will be fed down the
workpiece and add 1 mm. Single-insert boring operations with diameters greater than 20 mm can
be simulated more efficiently as nose turning operations (see Oblique and Nose Turning).
Fi g u r e 6 - 1 8 : Bo r i n g W o r k p i e ce w i n d o w
6.6 — Tapping Workpieces

Tapping workpieces are similar to Drilling Workpieces, but with the addition of a pilot hole with
chamfer. For workpiece width and length, it is recommended that users add 5-6 mm to the tap
diameter, which will allow 2-3 mm of extra room on either side.
82
3 D W or k pie ce Se t u p | Or bit a l D r illin g W or k pie ce s
Fi g u r e 6 - 1 9 : T a p p i n g W o r k p i e ce - En t r a n ce w i n d o w
6.7 — Orbital Drilling Workpieces

Similar to Drilling Workpieces, all orbital drilling workpiece parameters are the same, regardless of
simulation type (entrance, starting depth, or exit). The user needs to define the workpiece width,
height, and length. To minimize edge effects, extra margins should be added to the workpiece size
so that the workpiece is bigger than the combined drill diameter and diameter offset.
Orbital drilling also allows the user to specify a pilot hole or composite workpiece. For more
information, see Drilling Workpieces with Pilot Holes and Composite Drilling Workpieces.
Fi g u r e 6 - 2 0 : O r b i t a l D r i l l i n g W o r k p i e ce - St a r t i n g D e p t h w i n d o w
83
3 D W or k pie ce Se t u p | Or bit a l D r illin g W or k pie ce s
Truncated Orbital Drilling Workpieces
Truncated Orbital Drilling Workpieces allow users to focus on a small section of the workpiece, as
well as shorten simulation time. The four parameters used for workpiece truncation are the outer
radius, inner radius, start angle, and end angle. The section of the workpiece to be truncated
depends on whether the Orbital Drilling process is defined as clockwise or counterclockwise.
Fi g u r e 6 - 2 1 : O r b i t a l D r i l l i n g W o r k p i e ce - St a r t i n g D e p t h w i n d o w f o r cl o ck w i se o r b i t a l
d r i l l i n g w i t h T r u n ca t e W o r k p i e ce f e a t u r e se l e ct e d
Fi g u r e 6 - 2 2 : O r b i t a l D r i l l i n g W o r k p i e ce - St a r t i n g D e p t h w i n d o w f o r co u n t e r - cl o ck w i se
o r b i t a l d r i l l i n g w i t h T r u n ca t e W o r k p i e ce f e a t u r e se l e ct e d
84
3 D W or k pie ce Se t u p | Adva n ce d W or k pie ce Se t u p Opt ion s
6.8 — Advanced Workpiece Setup Options

Default workpieces exist for each 3D process and contain specific meshing parameters. The Initial
Meshing Parameters define the preliminary mesh before a simulation begins, capturing the original
geometry and defining a starting point for Adaptive Remeshing Parameters. These values,
populated by the 3D Graphical User Interface (GUI), are based specifically on the default setup for
each process. After meshing a case, the user can view the initial mesh by selecting V i e w M e sh .
Initial Meshing Parameters
When importing a tool or changing the default setup, the user may need to adjust the initial
workpiece meshing parameters. Altering these parameters may affect results; therefore, only
experienced users should adjust these values. To access initial workpiece meshing parameters,
select W o r k p i e ce > Cr e a t e / Ed i t St a n d a r d W o r k p i e ce , then click the A d v a n ce d O p t i o n s
button.
Fi g u r e 6 - 2 3 : Sa m p l e T u r n i n g W o r k p i e ce w i n d o w se t u p b e f o r e cl i ck i n g A d v a n ce d O p t i o n s
but t on
85
3 D W or k pie ce Se t u p | Adva n ce d W or k pie ce Se t u p Opt ion s
Fi g u r e 6 - 2 4 : A d v a n ce d O p t i o n s w i n d o w f o r w o r k p i e ce se t u p
Within the Advanced Options window the user can change the initial meshing parameters. These
parameters include:
• M a x i m u m El e m e n t Si z e — largest allowable element size within the workpiece mesh,

which occurs away from the cutting edge
• M i n i m u m El e m e n t Si z e — smallest allowable element size within the workpiece mesh,
which occurs near the cutting edge
• M e sh Gr a d i n g — determines the nature of the transition from fine elements near the cut-
ting edge, to coarse elements away from the cutting edge. This ranges from 0.1 to 1.0.
Decreasing this parameter will result in a slower transition between element sizes and conse-
quently, a more refined mesh. Similarly, a fast transition resulting in a coarser mesh occurs
with values closer to 1.
• Cu r v a t u r e - sa f e t y — defines the accuracy at which curved geometric features within the
model are captured by the mesh. This ranges from 0.2 to 5.0, where 0.2 represents a coarse
mesh.
• Se g m e n t s p e r Ed g e — determines the density of nodes on unit length of an edge within
the model. This ranges from 0.2 to 5.0, with 0.2 defining a coarse mesh.
• M i n i m u m Ed g e Le n g t h — minimum allowed edge length for any element in the mesh.
Geometric features smaller than this value will not be captured properly. By default the mini-
mum edge length is zero. It is recommended that the minimum edge length does not exceed
30% of the minimum tool element size.
Adaptive Remeshing Parameters
Workpiece adaptive remeshing parameters, which include chip bulk and cutter edge, are combined
with the workpiece Initial Meshing Parameters to determine the mesh while a simulation is running.
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3 D W or k pie ce Se t u p | W or k pie ce M a t e r ia ls
To adjust the adaptive remeshing parameters, select Si m u l a t i o n > Si m u l a t i o n O p t i o n s, then

click on the workpiece meshing tab.
Fi g u r e 6 - 2 5 : M e sh i n g P a r a m e t e r s w i n d o w
6.9 — Workpiece Materials

The Workpiece Materials window can be accessed by selecting W o r k p i e ce > M a t e r i a l . All
materials are constant between 2D and 3D simulations; for more information, see Workpiece
Materials
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CHAPTER 7 — 2D EXTERNAL FILE
IMPORTS
7.1 — DXF Tool Import

DXF files consist of multiple nodes created by an external CAD program. In AdvantEdge 2D, the
DXF Tool Import window allows a user to view the DXF entities along with the common numbered
nodes. Using the subsequent DXF Tool Viewer and Custom Tool Editor, the user can capture tool
geometry more adequately. For example, the cutting tool tip can be selectively refined to capture
fine scale features at the tip. To open the DXF Tool Import window, select T o o l > I m p o r t T o o l >
D X F T o o l Fi l e .
Click Br o w se to identify the DXF file to be imported. Once the file has been found, specify the DXF
file units that were used to save the DXF file. DXF file unit options are inches, millimeters, and
meters.
Fi g u r e 7 - 1 : D X F T o o l I m p o r t w i n d o w
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2 D Ex t e r n a l File I m por t s | D XF Tool I m por t
DXF Tool Viewer
The DXF Tool Viewer window allows users to view and refine the DXF tool previously imported using
the DXF Tool Import window.
Fi g u r e 7 - 2 : D X F T o o l V i e w e r w i n d o w
• Element size defines the one-dimensional edge mesh at a particular numbered point. This
number can be changed by selecting the desired point and entering a new value in the
Element Size box. After points have been selected and appear within the Point ID list, the
user can change the element sizes. To change the element size of a particular point, select
the desired point ID label, type a new value into the element size box, and click the Se t
El e m e n t Si z e button. The new element size value will now appear next to the point ID
label. Points can be selected using two methods:
 Click the Se l e ct P o i n t button, move the mouse to a desired point, and click on that
point. When selected, the point will turn green and its corresponding number and
element size will appear within the Point ID list.
 Click the Se l e ct R e g i o n button, then use the mouse to drag a selection box over
several desired points. All points within this box will be selected. These selected points
turn green and their corresponding numbers and element sizes appear within the point
ID list.
• Once a point is selected, it can easily be removed. Highlight the desired point ID and click the
R e m o v e Se l e ct e d button. The point ID will disappear from the box. To remove all
selections, click the R e m o v e A l l button.
• Z o o m — allows the user to zoom into the tool by dragging a selection box over a desired
area using the mouse. Alternatively, the R e se t V i e w button will reset the DXF Tool Viewer
to the original view.
90
N ot e : The zoom feature is not available when the Se l e ct R e g i o n option is activated.
• P a n — allows the user to move the tool up, down, left, or right within the window. To pan,
use the arrow keys on the keyboard.
• The Tool Mesh Viewer can be directly opened from the Tool Viewer window by clicking the
M e sh button. For complete details on Tool Mesh Viewer capabilities, see section 3.6.
Tool meshing parameters can be edited by clicking the A d v a n ce d O p t i o n s button within the DXF
Tool Viewer window. Within the Advanced Options window, users can change maximum tool ele-
ment size, minimum tool element size, and mesh grading.
• M a x i m u m / M i n i m u m El e m e n t Si z e — largest/smallest edge length for a coarsened/

refined element. Decreasing the element size has a quadratic increase in the computation
time. If the tool geometry is significantly smaller than the default values, a user should
decrease these parameters.
• M e sh Gr a d i n g — defines the transition between the largest element size and the smallest
element size. When an accurate temperature is desired farther up the tool body, the mesh
grading should be increased.
Fi g u r e 7 - 3 : A d v a n ce d O p t i o n s w i n d o w f o r D X F t o o l i m p o r t s
Custom Tool Editor
Upon closing the DXF Tool Viewer window, the Custom Tool Editor will open automatically. Here a
user can rotate the tool and add or delete points following DXF Tool Import.
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Fi g u r e 7 - 4 : Cu st o m T o o l Ed i t o r w i n d o w f o r D X F t o o l i m p o r t s
• A d d / D e l e t e P o i n t s — allows the user to add or delete a point, select the appropriate

button and use the mouse to click the point on the tool to be removed, or click on the
location where a point should be added.
• Ed i t — allows the user to move a point, reshaping the tool. When a point is selected by
clicking on it, it will become green. Click on a new location for the point; the point will move
to this location and become blue again.
• R e se t — returns to the original view
• U n d o — erases the last command performed
• R o t a t e — opens the Custom Tool Rotation window. Enter an angle in degrees that the tool
should be rotated.
Fi g u r e 7 - 5 : Cu st o m T o o l R o t a t i o n w i n d o w
• A d v a n ce d O p t i o n s — changes meshing parameters
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For a DXF Tool Import, mechanical and thermal boundary conditions can be edited within the Vertex
Parameters window. Right-click on the specific point to be edited within the Custom Tool Editor win-
dow, and the Vertex Parameters window will open. The X and Y parameters of the selected point will
be listed at the top of the Vertex Parameters window.
Fi g u r e 7 - 6 : V e r t e x P a r a m e t e r s w i n d o w
The mechanical boundary can be FixX, FixY, FixXY, or FreeXY:
• Fi x X — point is fixed in the X direction

• Fi x Y — point is fixed in the Y direction
• Fi x X Y — point is fixed in both directions
• Fr e e X Y — point is free to move
The thermal boundary may be defined as either adiabatic or a constant temperature. If constant
temperature is selected, a value must be entered in degrees Celsius.
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CHAPTER 8 — 3D EXTERNAL FILE
IMPORTS
Many AdvantEdge 3D simulations allow for NASTRAN Tool Import, STL/VRML Tool Import, or STEP
File Import. Below is a chart showing which file types — both tool and workpiece — can be imported
for specific operations:
Ta ble 8 .1 : File For m a t s Su ppor t e d for 3 D I m por t
Ope r a t ion & Tool Type N ASTRAN STL VRM L STEP
Turning
Oblique Turning X X X X
Nose Turning X X X X
Face Turning X X X X
OD Turning X X X X
Side Milling
Solid Side Milling X X X
Indexable Side Milling X X X
Stacked Side Milling X
Corner Milling
Solid Corner Milling X X X
Indexable Corner Milling X X X
Stacked Corner Milling X
Face Milling
Indexable Face Milling X X X
Ramp Milling
Solid Ramp Milling X X X
Indexable Ramp Milling X X X
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3 D Ex t e r n a l File I m por t s | N ASTRAN Tool I m por t
Ta ble 8 .1 : File For m a t s Su ppor t e d for 3 D I m por t
Ope r a t ion & Tool Type N ASTRAN STL VRM L STEP
Stacked Ramp Milling X
Plunge Milling
Solid Plunge Milling X X X
Indexable Plunge Milling X X X
Pocket Milling
Solid Pocket Milling X X X
Indexable Pocket Milling X X X
Drilling
Solid Drilling X X X
Indexable Drilling X
Grooving
Standard Tool Grooving X X X X
Cone Tool Grooving X X X X
OD Grooving X X X X
Boring
Boring X X X X
Tapping
Tapping X
8.1 — NASTRAN Tool Import

To import complete custom tool geometries into AdvantEdge, NASTRAN or STL/VRML Tool Import
files are required. These files can contain tool volume mesh or surface mesh. Users can also
prescribe edge radii or hones, if not already included in the basic geometries.
Exporting NASTRAN Files
NASTRAN files are very common finite element formats, and most meshing software can create
files in NASTRAN format. When exporting a NASTRAN file for AdvantEdge import, users should be
aware of the following constraints:
• El e m e n t T y p e — For surface mesh use only 3 node triangle elements. For volume mesh,
use only 4 node tetrahedral elements.
• N A ST R A N Fo r m a t — Long and comma separated NASTRAN formats are both supported;
however, fixed format is currently not supported
• Or ie n t a t ion
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3 D Ex t e r n a l File I m por t s | N ASTRAN Tool I m por t
 Tool rake face must be on the YZ plane

 Normal to the rake face or the cutting direction must point in the negative X direction
 Feed direction must point in the positive Z direction
 DOC must be in the negative Y direction. For nose Turning, DOC is measured from the
largest Y value on the tool.
 Workpiece (oblique turning only) must be centered relative to the Y axis
 Tool holder angles (input during import) must be zero
Fi g u r e 8 - 1 : N A ST R A N t o o l o r i e n t a t i o n
• M e sh Q u a l i t y — NASTRAN file will be imported directly; no edge preparation or further

mesh refinement occurs. Therefore, it is important that the mesh quality is good prior to
importing.
N ot e : Axes will change when simulated in AdvantEdge.
Importing NASTRAN Files
To open the NASTRAN Tool Import window, select T o o l > I m p o r t T o o l > N A ST R A N Fi l e .

Within the NASTRAN Tool Import window, click the Br o w se button and locate the file to be
imported. AdvantEdge will make a copy of this file, called projectname.nst. Once the file has been
copied, click V i e w to preview the file.
The NASTRAN Tool Import window also allows users to input tool holder angles, lead angle, edge
radius, and the number of edge facets.
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3 D Ex t e r n a l File I m por t s | STL/ VRM L Tool I m por t
Fi g u r e 8 - 2 : N A ST R A N T o o l I m p o r t w i n d o w
Fi g u r e 8 - 3 : N A ST R A N sa m p l e t o o l p r e v i e w i n T e cp l o t . Si d e a n g l e i s a b o u t t h e Y a x i s, b a ck
a n g l e i s a b o u t t h e Z a x i s, a n d l e a d a n g l e i s a b o u t t h e X a x i s.
8.2 — STL/VRML Tool Import

VRML and STL files are both lists of triangular surfaces that describe a computer generated solid
model. The AdvantEdge tool import interface allows users to import 3D STL/VRML tool files and
immediately view the tool orientation and shape to ensure proper setup. While viewing the tool,
98
users may also rotate, translate, and/or truncate the tool. AdvantEdge guidelines provided within
the interface will help direct the user to the appropriate tool orientation. By truncating the tool
along a specified axis, users can reduce the simulation time.
Exporting STL/VRML Files
In order to use the STL/VRML import function, a STL/VRML file must first be created from another
program. To ensure that the STL/VRML file can later be imported into AdvantEdge, please note the
following constraints:
• El e m e n t T y p e — for surface mesh, use only 3 node triangle elements

• M e sh Q u a l i t y — not important; AdvantEdge will re-mesh the file after importing
• ST L Fo r m a t — the STL file can be in binary or ASCII format. The ASCII STL file must start
with the lower case keyword solid and end with the lower case keyword endsolid.
Importing STL/VRML Files
To import STL/VRML files into AdvantEdge, open the Tool Import window by selecting T o o l >
I m p o r t T o o l > ST L T o o l Fi l e or V R M L T o o l Fi l e .
Fi g u r e 8 - 4 : V R M L T o o l I m p o r t w i n d o w
1. Select the file by clicking the Br o w se button located within the Tool Import window.
Once selected, the file name will appear in the STL/VRML Tool File area.
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2. Select the file units; this selection (mm or inches) states which units correspond to the
STL/VRML file
3. Input the desired resolution, lead angle, side tool holder angle, back tool holder angle,
and advanced mesh options
N ot e : Tool resolution is the number of divisions along the longest edge of the tool. The
larger the resolution value, the more accurate the imported model will be. For best
results, the resolution should be around 200. If the resolution is too large, the tool
may encounter problems while meshing.
4. Open the Tool Orientation window by clicking the V i e w button. After a few seconds, the
Tool Orientation window will open and display the 3D STL/VRML file.
 Ch e ck O r i e n t a t i o n t a b — allows users to rotate and translate tools as needed. All

translations will be performed according to the units specified in step two. Rotations and
translations will automatically be applied to the tool, allowing the user to view changes
as they are executed. Once the correct orientation is displayed, click the Sa v e button. If
truncation is not needed, click the O K button to close the Tool Orientation window and
return to the normal AdvantEdge window.
Fi g u r e 8 - 5 : Ch e ck O r i e n t a t i o n t a b o f T o o l O r i e n t a t i o n w i n d o w
100
 T r u n ca t e Ge o m e t r y t a b — allows users to truncate the tool in the X direction,

Y direction, Z direction, or any combination of these three. Once a truncation direction is
selected, a truncation plane and truncation directional arrow will appear on the tool. The
plane should be perpendicular to the truncation direction selected. The truncation direc-
tional arrow indicates the direction in which truncation will occur. Every portion of the
tool from the truncation plane in the direction of the arrow will be ignored. This direction
can be flipped back and forth by toggling the Fl i p D i r e ct i o n radio buttons. To move
the truncation along the selected axis, use the slide bar or the arrows provided.
N ot e : When defining multiple truncation directions, each truncation direction plane will
appear as a different color. These colors correspond to the axes colors, helping
users to identify each plane.
Fi g u r e 8 - 6 : T r u n ca t e Ge o m e t r y t a b o f T o o l O r i e n t a t i o n w i n d o w
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3 D Ex t e r n a l File I m por t s | STEP File I m por t
Fi g u r e 8 - 7 : T r u n ca t e Ge o m e t r y t a b o f T o o l O r i e n t a t i o n w i n d o w w i t h m u l t i p l e t r u n ca t i o n
d i r e ct i o n s d i sp l a y e d
The A d v a n ce d button in the Tool Import window allows the user to define Runout and Differential
Pitch when applicable. Since these options only apply to certain milling and drilling processes, the
Advanced button will appear grey for the other processes.
8.3 — STEP File Import

AdvantEdge features a STEP Analyzer to assist users in viewing imported tools (T o o l s > I m p o r t
T o o l > ST EP T o o l Fi l e ) and imported workpieces (W o r k p i e ce > I m p o r t W o r k p i e ce >
ST EP W o r k p i e ce Fi l e ). This feature allows users to open any STEP file exported from
commercial CAD systems and visualize them in the AdvantEdge environment. The table below
shows a matrix of STEP tool and workpiece import capabilities within AdvantEdge
Ta ble 8 .2 : Adva n t Edge 3 D STEP Tool a n d W or k pie ce I m por t Ca pa bilit ie s
St a n da r d W or k pie ce I m por t e d W or k pie ce
Standard Tool Import X
Tool Only Import X
Tool–Workpiece Import X X
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STEP File Components
STEP files contain definitions of exported CAD objects in terms of Boundary-Representations (B-
Rep).
Geometries are defined by two types of entities: geometric and topological. Geometric entities
include points, vectors, directions, curves, and surfaces. Topological entities contain geometries as
well the relationship among the entities. Part geometries are generally described in STEP files using
the following entities:
• V e r t i ce s — points in space
• Ed g e s — curves with two vertices as their end points
• Lo o p s — set of topologically connected edges
• Fa ce s — defined using loops and contain direction normals
• Sh e l l s — sets of connected faces. Can be open or closed depending on the topology in the
STEP file and the tolerance given to the proximity of the entities.
• So l i d s — volumes enclosed in a closed shell
STEP files may contain any number of topological entities. However, since AdvantEdge generates
volume mesh for imported tools, STEP files are expected to contain a single solid made up of a
single shell object. Any entities not contributing to the geometry of the solids in the STEP file are
considered to be free. AdvantEdge can sometimes build a solid volume out of a set of shells. A solid
volume is always considered as free. For the purposes of AdvantEdge, shells are also considered
free without qualification. All other entities that are not a part of a shell or solid, are described
hereafter as free entities.
Rarely, exported STEP files may accidentally contain free vertices, free edges, and/or free shells.
Such entities must be eliminated from the STEP file before AdvantEdge can successfully use the file.
For more, see STEP File Case Studies and Troubleshooting.
Importing STEP Tool Files
The STEP Tool Import window is used to import STEP files by selecting T o o l > I m p o r t T o o l >
ST EP T o o l Fi l e . Users can browse to any directory to open the required STEP file. There are tabs
in the STEP Tool Import window for importing either a Tool Only Import, or a Tool–Workpiece Import
combination. Advanced Options are also available within this window.
TOOL ON LY I M PORT
Tool only import is the default option when Importing STEP Tool Files. This feature allows users to
import a single insert geometry using STEP files and specify parameter definitions such as number
of inserts required, tool holder angles, etc. Once imported, a solid or indexable tool file can be
rotated and translated within the STEP Analyzer. If inserts are imported according to the tool
orientation requirements specified in the STEP Analyzer, AdvantEdge will automatically generate all
remaining inserts based on the parameters specified.
103
Fi g u r e 8 - 8 : T o o l O n l y I m p o r t t a b o f ST EP T o o l I m p o r t w i n d o w
TOOL– W ORKPI ECE I M PORT
The Tool–Workpiece Import tab should be used when Importing STEP Tool Files for 3D solid mills,
solid drills, indexable drill/mill assemblies, and stacked helical mills (for more, see 3D Tool Setup).
For these tools, the imported files are immediately meshed without user-defined coordinate
transformation or parametric replication into multiple inserts. Users are expected to provide the
correct relative positioning and orientation between multiple inserts. For correct positioning
however, AdvantEdge still requires users to orient the tool so that the tool rotation axis is aligned
with the global Z-axis. For turning and grooving processes, AdvantEdge automatically uses the
global coordinate system of the imported STEP file for final simulation. Inserts are imported on an
“as is” basis and meshed for simulation. No additional transformations are performed.
Fi g u r e 8 - 9 : T o o l – W o r k p i e ce I m p o r t t a b o f ST EP T o o l I m p o r t w i n d o w
104
The STEP Tool Import window will only load the STEP tool file; however, using the Tool–Workpiece
Import tab will alert AdvantEdge to the use of both STEP tool and workpiece files. For more, see
Importing STEP Workpiece Files.
N ot e : Since no automatic boundary conditions are applied to a tool–workpiece STEP

import, the user will need to define boundary conditions using the STEP Analyzer.
Once the STEP file is selected for import, the contents of the selected file are automatically copied
to the local project directory with the name projectname.stp. This new file will be used for all the
downstream simulation purposes. Changes made to the STEP file are only applied to this new file;
the original STEP file is not affected. To save a revised STEP file, select T o o l > Sa v e T o o l A s.
Preview the STEP file in AdvantEdge by clicking the Ch e ck / O r i e n t T o o l button.
Fi g u r e 8 - 1 0 : ST EP T o o l I m p o r t f l o w ch a r t
To open the Advanced Options window while Importing STEP Tool Files, select T o o l > I m p o r t
T o o l > ST EP T o o l > A d v a n ce d O p t i o n s. This window can be accessed during initial STEP tool
import, or after the tool has been loaded into the STEP Analyzer. Once all advanced options
parameters have been defined, click O K to save changes.
Tool Meshing
All parameters in the Tool Meshing tab of the STEP Tool Import Advanced Options window vary the
tool mesh. Any modifications made to these parameters can significantly affect the mesh;
consequently, only experienced users should make changes.
105
Fi g u r e 8 - 1 1 : T o o l M e sh i n g t a b o f ST EP T o o l I m p o r t - A d v a n ce d O p t i o n s w i n d o w
• M e sh Gr a d i n g defines the transition between the largest element size and the smallest
element size. When an accurate temperature is desired further up the tool body, the mesh
grading should be increased. Increasing the mesh grading will also increase the computation
time
• Cu r v a t u r e - Sa f e t y controls the smoothness of a surface. When this value is increased, the
curve’s mesh will create a smoother surface.
• Se g m e n t s p e r Ed g e is the number of divisions on the tool’s edge. Increasing this number
will increase the number of elements on the edge.
• M i n i m u m Ed g e Le n g t h is the length of the smallest edge on the surface. If a segment of
the tool is smaller than the user-defined minimum, an edge will not be captured by the mesh
properly. For this reason, a user should always view a finished mesh in order to correctly
capture the geometry.
• M a x i m u m / M i n i m u m El e m e n t Si z e refers to the largest/smallest edge length for a
coarsened/refined element. Decreasing the element size has a quadratic increase in the
computation time. Decrease these parameters if the tool geometry is significantly smaller
than the default values.
N ot e : The Near Tip Tool Element Refinement Factor is used to define the smallest tool
element size. Refinement factor is the ratio of maximum tool element size to
minimum tool element size, and can be used to refine cutting edge radius and chip
breaker geometries. Number should range from 1 to 20. Numbers larger than 20
can be used, but are not recommended.
106
Fi g u r e 8 - 1 2 : Gu i d e l i n e s f o r se t t i n g t o o l m e sh e l e m e n t si z e
Cut t er Body Meshing
The cutter body meshing feature is available for AdvantEdge 3D indexable milling and indexable
drilling processes when Importing STEP Tool Files. It allows the user to specify the cutting inserts
and tool cutter body solids in an imported STEP assembly file. Any modifications made to these
parameters can significantly affect the mesh; consequently, only experienced users should make
changes.
Fi g u r e 8 - 1 3 : Cu t t e r Bo d y M e sh i n g t a b o f ST EP T o o l I m p o r t - A d v a n ce d O p t i o n s w i n d o w
• M a x i m u m / M i n i m u m El e m e n t Si z e refers to the largest/smallest edge length for a

coarsened/refined element. Decreasing the element size has a quadratic increase in the
107
computation time. Decrease these parameters if the tool geometry is significantly smaller
than the default values.
• M e sh Gr a d i n g defines the transition between the largest element size and the smallest
element size. When an accurate temperature is desired further up the tool body, the mesh
grading should be increased. Increasing the mesh grading will also increase the computation
time.
• Cu r v a t u r e - Sa f e t y controls the smoothness of a surface. When this value is increased, the
curve’s mesh will create a smoother surface.
• Se g m e n t s p e r Ed g e is the number of divisions on the tool’s edge. Increasing this number
will increase the number of elements on the edge.
• M i n i m u m Ed g e Le n g t h is the length of the smallest edge on the surface. If a segment of
the tool is smaller than the user-defined minimum, an edge will not be captured by the mesh
properly. For this reason, a user should always view a finished mesh in order to correctly
capture the geometry.
Runout Param et ers
Runout that occurs in some milling processes may become non-negligible. In order to capture this
occurrence, check the R u n o u t O N / O FF checkbox at the top of the Runout Parameters tab of the
Advanced Options window. Once a user has selected to include runout in the analysis, a coordinate
system must be designated. Two choices are possible:
• Ca r t e si a n Co o r d i n a t e Sy st e m — Enter the runout in the X and Y directions. The

maximum allowable runout radius is 100 microns.
Fi g u r e 8 - 1 4 : R u n o u t P a r a m e t e r s t a b o f ST EP T o o l I m p o r t - A d v a n ce d O p t i o n s w i n d o w w i t h
Ca r t e si a n co o r d i n a t e sy st e m se l e ct e d
• P o l a r Co o r d i n a t e Sy st e m — Enter the runout radius and angle. The maximum allowable

runout radius is 100 microns.
108
Fi g u r e 8 - 1 5 : R u n o u t P a r a m e t e r s t a b o f ST EP T o o l I m p o r t - A d v a n ce d O p t i o n s w i n d o w w i t h
P o l a r co o r d i n a t e sy st e m se l e ct e d
Different ial Pit ch
Differential pitch cutters contain unevenly spaced inserts, and have different harmonics than
cutters with evenly spaced inserts. Differential pitch cutters are often used to reduce vibrations. To
capture this feature of the cutter, the user must check the D i f f e r e n t i a l P i t ch checkbox located at
the top of the Differential Pitch tab of the Advanced Options window. This feature is only available
for the indexable milling process.
Fi g u r e 8 - 1 6 : D i f f e r e n t i a l P i t ch t a b o f ST EP T o o l I m p o r t - A d v a n ce d O p t i o n s w i n d o w
In AdvantEdge, inserts are referred to as teeth. For every tooth present in the assembly, an angle is
used to determine its location in relation to tooth one. Thet a2 is the angle between tooth one and
109
tooth two, Thet a3 is the angle between tooth one and tooth three, and so on. All differential pitch
angles should be at least 15 degrees apart.
N ot e : AdvantEdge will assume that main cutting insert solids do not overlap. This should
be verified by the user when the STEP file is originally exported from the CAD
software.
STEP Analyzer
When viewing a STEP File Import, the STEP Analyzer within AdvantEdge provides several CAD-like
menu options including zoom, pan, rotate, and save. In addition, the viewer allows users to orient
imported tools to meet the requirements AdvantEdge holds for the specified process (for more, see
Importing STEP Tool Files). Should the user make a mistake, the STEP Analyzer also allows for
resetting the orientation to its original position and re-orienting the tool to the appropriate
orientation. Users are also able to save re-oriented files with different file names.
There are various viewing options that can be selected and/or activated within the AdvantEdge 3D
Graphical User Interface (GUI). Actions most relevant to the STEP Analyzer are:
• Rotate — left mouse button
• Pan — right mouse button
• Zoom — middle mouse button
The STEP Analyzer also allows users to Check Geometry for invalid surfaces, assign Selective Mesh
Refinement on cutting edges or features, assign mechanical Boundary Conditions, Check
Orientation to verify that they meet the requirements for the machining process being modeled,
and set Cutter Definition. Each of these important submenus offers users a variety of parameter
options.
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Fi g u r e 8 - 1 7 : ST EP A n a l y z e r t a b s
CH ECK GEOM ETRY
Generating a desired geometry in a CAD system can be achieved by using two main modeling
approaches:
• Co n st r u ct i v e So l i d Ge o m e t r y ( CSG) is a solid model-based approach that calculates

various geometric features through Boolean operations such as addition (union), subtraction
(difference), and intersection operations. These operations are performed on a set of pre-
defined solid objects (primitives such as cubes, spheres, cylinders, prisms, pyramids and
cones); for uncommon primitives, sweeping of a 2D cross-section in the form of extrusion
and revolving are used to define the 3D shape. The final geometry is recreated by taking
these primitives and re-performing the same set of Boolean operations (or procedures).
Since it uses simple geometry primitives, the CSG approach is not capable of representing
higher-level geometric entities.
• Bo u n d a r y - R e p r e se n t a t i o n ( B- r e p ) models each object using a collection of boundary
surfaces. A set of closed surfaces forms a surface model, while an enclosing volume
represents the solid. Programs record both the surface geometry and the topological
relations among these surfaces. Most current CAD systems use Non-Uniform Rational B-
Spline (NURBS) to model B-Rep surfaces in a 3D CAD model.
Common CAD systems such as Pro/E, CATIA, and UGS allow users to use both CSG and B-Rep
approaches when creating final geometries, combining the simplicity of CSG with the power of B-
Rep. 3D modeling performed with a combination of solid- (CSG) and surface- (B-rep) based
operations is termed “hybrid” modeling. Internally, each CAD system has its own representation of
the CAD geometry and geometric constants (e.g. tolerance) that lead to interoperability problems
between various CAD systems and other software (e.g. AdvantEdge).
The data-exchange standard STEP (STandard for the Exchange of P roduct model data—ISO
10303) file defines a neutral file format to represent product geometry and requires the geometry
to be represented as a B-rep. It is designed to enhance interoperability among different CAD
systems, independent of their native representation of geometry.
A clean solid model will have a hierarchy of volume, faces, edges and points where all entities are
unambiguously defined. However, features such as slivers, minute edge lengths, tangencies and
patchworks of faces that attract unnecessary elements meet “clean” modeling specifications, yet
may still create meshing algorithm problems.
In many cases, the edge curves of solid models only approximate the actual intersection of two
surfaces. In order to compute the precise intersection of two NURBS surfaces, the surfaces must be
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described by a 54th-order polynomial. However, in order to reduce the computation to more

manageable levels, most CAD systems settle for approximating the intersection by a cubic (third-
order) polynomial. The edge curve defined usually lies close to, but not precisely on, the two
surfaces it bounds. Because of these approximations, there are gaps between the edges and faces
of solids. These gaps are the source of several translation and meshing errors.
In order to successfully complete a simulation in AdvantEdge, users should follow some basic rules
for exporting STEP files. The following content describes common problems encountered when
exporting STEP files, possible remedies, and useful guidelines for the STEP data exchange.
The figure below provides a flowchart of steps AdvantEdge users can follow in order to obtain
successful simulations:
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Fi g u r e 8 - 1 8 : M e sh i n g m e t h o d s f l o w ch a r t
Tolerances
To Check Geometry using the STEP Analyzer, having an understanding of tolerances and methods
for evaluating tolerances is important to appropriately using CAD geometries for mesh generation.
One of the key areas influenced by tolerances and their associated methods is that of tangencies
and near tangencies. The algorithms used in CAD system modeling engines are written to deal with
tolerances in a consistent manner. However, these algorithms are not available outside of CAD
systems; therefore, translated data introduces “dirty” geometry.
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One of the most common problems during CAD file translation is differences in tolerance value
between the sending and receiving CAD systems. For example, a solid model created in a system
using an internal tolerance of 10E-3 mm would have a numeric data representation of 0.001 mm.
At this tolerance, surfaces successfully share necessary common edges, trim curves successfully lie
on necessary surfaces, and so on. However, when the data is translated to a system using an
internal tolerance of 10E-6 (0.000001 mm), the receiving system will be looking for two adjacent
surfaces within 0.000001 units of each other. Since the numeric data submitted is only accurate to
0.001 units, the receiving system will not be able to generate a solid from the translated data. In
general, tolerance problems are due to inherent differences in the way two CAD applications were
programmed.
Tolerance problems can also exist in both directions: loose and tight. Going from a loose to a tight
tolerance system will typically result in gapping issues (gaps between surfaces, untrimmed
geometry, etc). Going from a tight to a loose tolerance system will typically result in realism issues
(sliver surfaces, edges with near zero length, etc.). Loose tolerance CAD systems such as CATIA
and I-DEAS have an internal geometric tolerance of around 0.1 and 0.01 mm. Tight tolerance
systems such as Unigraphics, SolidWorks, SolidEdge, Mechanical Desktop, and Inventor have an
internal geometric tolerance of around 0.000001 mm.
Some modeling systems, including AdvantEdge, include “healing” functions to assist users with
fixing tolerance errors (see Healing Imported STEP Files); however, without knowledge of the
modeling system tolerances and methods, there is no a priori means to ensure that a healing
function will successfully recover the correct model representation.
SELECTI VE M ESH REFI N EM EN T
By default, AdvantEdge will auto-detect and apply a refined mesh on tool cutting edges. By using
selective mesh refinement, the user can select any number of faces or edges on a step file and
specify the minimum element size desired. By only refining certain cutting edges, the tool will have
a smaller number of elements and the simulation will take less time to compute. Selective mesh
refinement also allows refinement of specific geometries in a STEP file that are not detected as
cutting edges.
To select individual edges or faces for mesh refinement, select the Mesh Refinement submenu tab
within the STEP Analyzer, zoom in to the area of interest and CTRL+left mouse click on the desired
edge or face. To select multiple edges or faces for mesh refinement, SHIFT+left mouse click and
select all desired edges or faces.
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Fi g u r e 8 - 1 9 : M e sh R e f i n e m e n t t a b o f ST EP A n a l y z e r w i n d o w w i t h st e p s t o se l e ct i n d i v i d u a l
e d g e s/ f a ce s f o r m e sh r e f i n e m e n t
After all desired edges/faces have been selected, click the Ed i t Se l e ct i o n button to specify a
minimum element size. AdvantEdge will display a list selected faces and edges, along with a field
for entering minimum elements. Enter the appropriate element size, then click A d d to apply the
size to the selected entities. To remove entities from the list, select the face or edge, then click
Re m ov e .
Fi g u r e 8 - 2 0 : A d d / R e m o v e Se l e ct e d En t i t i e s w i n d o w
The STEP Analyzer will highlight all selected edges and faces, and also display their entity IDs.
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Fi g u r e 8 - 2 1 : M e sh R e f i n e m e n t t a b o f ST EP A n a l y z e r w i n d o w a f t e r f a ce se l e ct i o n
CH ECK ORI EN TATI ON
When the user selects a STEP tool file, the STEP Analyzer will automatically save the file in the
current directory as projectname.stp. The primary function of the Check Orientation tab of the STEP
Analyzer is to allow users to input the tool axes (X is [1,0,0], Y is [0,1,0], Z is [0,0,1]) and angle
(counter-clockwise is +ve, clockwise is –ve) for proper process orientation. After these values have
been entered, click the R o t a t e button to rotate the tool. To undo all the recent changes click the
R e se t button; AdvantEdge will re-import the tool from projectname.stp.
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Fi g u r e 8 - 2 2 : Ch e ck O r i e n t a t i o n t a b o f ST EP A n a l y z e r w i n d o w
• Ch a n g e T o o l O r i e n t a t i o n — All entities in the STEP file are automatically selected in the

Check Orientation tab. The tool can be rotated or translated by defining the axis of rotation,
center of rotation, and angle of rotation. Once these variables are defined, click the R o t a t e
button. To translate the tool, the user must define the axis of rotation located at the center of
the tool, and click the T r a n sl a t e button. The STEP Analyzer will automatically update after
each rotation or translation.
Help tips for orienting imported tools are included in the STEP Analyzer window and differ for each
process. To view these tips, click the H e l p button located underneath the Tool Orientation Guide,
near the bottom of the Check Orientation tab.
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Fi g u r e 8 - 2 3 : ST EP I m p o r t H e l p w i n d o w f o r so l i d e n d m i l l i n g t o o l
• Sa v i n g t h e O r i e n t e d Fi l e — In order to save the newly-oriented tool file, click either

Sa v e or O K
 The Sa v e button will save all changes to the file while keeping the STEP Analyzer open
 The O K button will save all changes to the file and close the STEP Analyzer
 The Sa v e A s button will save all changes to the file under a different name (creating
the possibility of saving the file to a centralized STEP file repository). The user can then
browse to a desired directory and save the file as a specific name. The STEP Analyzer
will remain open.
As a default setting, any time the user clicks O K or Sa v e , the STEP file is saved in the current
project directory under the name projectname.stp.
N ot e : If the Check Orientation tab within the STEP Analyzer is closed by clicking either the
[ X ] button or the Ca n ce l button, recent changes in orientation will be discarded.
STEP I m port Tool Orient at ion Guidelines
• Indexable Milling Orientation:

 Tool need not be positioned at the origin; AdvantEdge automatically translates. Use the
Check Orientation tab to orient the tool correctly.
 Only one insert should be modeled. Other inserts will be created automatically.
 Tool rotates about the Z axis in a downward direction
 Feed direction must be in the positive Y direction
 DOC must be in the negative Z direction
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 To apply boundary conditions correctly, the back face should be planar and aligned par-
allel to the YZ plane
 All tool holder angles must be zero. These angles can be input in the STEP Analyzer.
• Solid End Milling Orientation:
 Tool axis should be the same as Z axis
 For solid end mills and ball-end mills, the end of the tool should be pointing in the nega-
tive Z direction
• Drilling Orientation:
 Tool axis should be the same as Z axis
 Chisel edge should be pointing in the negative Z direction
• Indexable Drilling Orientation:
 Only one insert should be modeled. Other inserts will be created automatically.
 Tool rotates about the Z axis in a downward direction
 Feed direction must be in the positive Y direction
 DOC must be in the negative Z direction
 To apply boundary conditions correctly, the back face should be planar and aligned par-
allel to the YZ plane
 Relative dimensions between the outer and inner inserts can be defined in the STEP
Analyzer. If the inner insert is different from the outer insert, the Unique Inserts bullet
can be activated and two separate STEP files can be imported.
• Oblique Turning Orientation:
 Cutting direction should point in the negative X direction
 Feed direction must be in the negative Z direction
 DOC must be in the negative Y direction
 Workpiece is centered relative to the Y axis
• Nose Turning Orientation:
 Cutting direction should point in the negative X direction
 Feed direction should point in the negative Z direction
 DOC must be in the negative Y direction
 DOC is measured from the largest Y value on the tool
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• Grooving Orientation:
 Cutting direction needs to point in the negative X direction
 Feed direction needs to be in the negative Y direction
 Tool should have the largest portion of the workpiece at the cutting edge when using an
initial depth. This will ensure a more accurate pre-cut profile.
Rem arks on STEP File Translat ions
One of the most common problems during CAD file translation is differences in tolerance value
between the sending and receiving CAD systems. For a thorough explanation of tolerances and
some troubleshooting tips, see Tolerances.
The Boundary Conditions tab of the STEP Analyzer allows users to define displacement boundary
conditions for a Tool–Workpiece Import while simultaneously viewing the tool. All nodes selected
will be fixed in the X, Y, and Z directions. The user may define displacement boundaries; however,
thermal boundary conditions are automatically applied as necessary. Once a boundary condition is
set by the user, the boundary will always be applied unless removed by the user.
N ot e : The Boundary Conditions tab is only available for a combined Tool–Workpiece

Import.
Fi g u r e 8 - 2 4 : Bo u n d a r y Co n d i t i o n s t a b o f ST EP A n a l y z e r w i n d o w
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Adding/ Rem oving Boundary Condit ions
1. Select the desired face by clicking on desired elements:

 Individual Element Selection — CTRL+left mouse click
 Continuous Element Selection — SHIFT+left mouse click
2.Click the Ed i t Se l e ct i o n button to open the Add/Remove Selected Faces window. The
Ca n ce l button will disregard any changes made within this window.
Fi g u r e 8 - 2 5 : A d d / R e m o v e Se l e ct e d Fa ce s w i n d o w
Once the entry has been added, the boundary condition will appear within a table on the Selective
Boundary Conditions window. On the table the entry type, ID, and displacement will all be listed.
The R e m o v e A l l button will remove all boundary conditions listed within the table.
To view the boundary conditions, click R e d r a w A l l . The current boundary conditions will turn
green on the tool and/or workpiece.
CUTTER D EFI N I TI ON
The Cutter Definition tab of the STEP Analyzer provides a list of parts contained within the
assembly, along with entry ID labels. To define a part within the assembly, entry ID labels must be
selected. Users can then set each part as an insert, body, or excluded solid.
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Fi g u r e 8 - 2 6 : Cu t t e r D e f i n i t i o n t a b o f ST EP A n a l y z e r w i n d o w
• I n se r t s are solids that actively participate in removing material. Once a part is designated
as an insert, it appears yellow within the assembly. Inserts are modeled as elastic bodies.
• Bo d i e s are solids that orient the insert in the correct position for material removal. Once a
part is designated as a cutter body, it appears grey within the assembly. As a default, cutter
bodies are modeled as rigid solids. To change this setting and define the cutter body as an
elastic body, select Si m u l a t i o n > Si m u l a t i o n O p t i o n s and check the Cu t t e r Bo d y
M o d e l e d a s D e f o r m a b l e checkbox under the General Options tab of the 3D Simulation
Options window.
• Ex cl u d e d Bo d i e s are solids that are excluded from finite element meshing and analysis.
Once a part is designated as an excluded body, as a default, it will no longer appear in the
assembly. However, the entry type and ID label will still appear in the Cutter Body Definition
table, but with red letters. Excluded solids will still remain intact in the original STEP file.
The D i sp l a y O p t i o n s button within the Cutter Definition tab of the STEP Analyzer allows a user to
select which of the three solids should be displayed in the 3D Graphical User Interface (GUI). Users
can select any combination of inserts, cutter bodies, and excluded solids to display. As a default,
inserts and cutter body are shown.
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Fi g u r e 8 - 2 7 : Cu t t e r D i sp l a y O p t i o n s w i n d o w
Importing STEP Workpiece Files
Once a STEP tool file has been defined using the Tool–Workpiece Import tab of the STEP Import
window, a STEP workpiece file can be imported into AdvantEdge. To load a STEP workpiece file,
select W o r k p i e ce > I m p o r t W o r k p i e ce > ST EP W o r k p i e ce Fi l e . Browse to the desired
STEP file and click V i e w W o r k p i e ce to open the STEP Analyzer.
N ot e : STEP workpieces can only be loaded in conjunction with STEP tools. For more, see
Importing STEP Tool Files.
Fi g u r e 8 - 2 8 : ST EP W o r k p i e ce I m p o r t w i n d o w
Once a STEP workpiece has been loaded into AdvantEdge, the STEP Analyzer will automatically
check for bad geometry. Rotations and translations applied to the imported STEP workpiece must
also be applied to the STEP tool for correct alignment. While there is no option for mesh refinement
on the workpiece, mechanical Boundary Conditions must be specified before the workpiece is
considered ready for simulation. Displacement boundary conditions will automatically be set in the
XYZ direction on the selected face.
Preparing STEP Files for AdvantEdge Import
When creating STEP files for future STEP File Import into AdvantEdge, the following guidelines
should be followed:
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SOLI D M OD ELI N G
It is important to check the validity of the volume in the native CAD software. The part must be a
closed solid volume, and NOT a surface model. In some cases, a closed shell can be exported and
successfully meshed in AdvantEdge; however, STEP file healing may be required for many of these
cases (see Healing Imported STEP Files).
TOLERAN CE ACCURACY
It is important to have a good Tolerances on parts prior to exporting. Values should be 0.001 mm or
smaller. It is preferable to set a narrow tolerance at the start of modeling — especially when using
CATIA (e.g. in CATIA: IDENTICAL CURVES).
TESTI N G
After exporting a STEP file, it is always useful to import the file back into the original CAD package.
If the file cannot regenerate a solid or closed object, it is highly likely that meshing errors will occur
in AdvantEdge. Users should also look for and eliminate overlapping surfaces, as these often lead to
overlapping meshes in AdvantEdge, as well as meshing failure. For more, see Check Geometry.
FI LE FORM ATTI N G ERRORS
The following decisions may prevent the STEP Analyzer from reading the imported STEP files
properly, and should be addressed prior to exporting from CAD software:
• Special characters in the STEP file (such as Unicode) may be included in the non-geometric
product definition section of the STEP file. Removing these special characters will result in
successful reading of the file.
• References to missing or non-existent geometric entities are most likely caused by omission
by the STEP file writer or corruption of the file after exporting; see Healing Imported STEP
Files for suggestions on resolving this issue.
STEP EXPORT GUI D ELI N ES FOR UGS USERS
The translation of UGS solid geometry is complex and is dependent on a number of factors.
Unfortunately, errors and failures do occur. Many STEP translation failures and errors occur due to
user modeling practices and/or CAD system algorithm errors. To reduce and eliminate translations
the user must prepare, validate, and possibly repair the solid model geometry before attempting to
use the STEP translator. An excellent resource for Unigraphics users in dealing with STEP files is a
document provided at www.cax-if.org/bestprac/stepbpg.htm. This document describes data
exchange between different CAD systems; however, the following guidelines have been tailored for
AdvantEdge users who make use of Unigraphics when creating geometries:
1. Try to eliminate modeling practices that lead to the creation of un-parameterized fea-
tures. This will greatly reduce corrupt solids and will facilitate the repair of invalid geom-
etry errors if they do occur.
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2. Visually inspect the fully shaded Unigraphics solids to be translated. If any faces are
“missing,” they must be repaired or deleted from the model.
3. Save a copy of the part file with all blend features suppressed or deleted; the Unigraphics
blend feature is not directly supported by STEP files and may cause errors in AdvantEdge.
If translation failures or errors occur using the original part with blends, translate the
copy without blends.
4. Select Fi l e > U t i l i t i e s > P a r t Cl e a n u p . The Part Cleanup feature will eliminate cer-
tain inaccessible objects from the part file. Specify the following cleanup operations to be
performed on the part:
 Delete all empty and/or unnamed groups
 Turn off all object highlighting
 Delete all unused (un-referenced) objects
 Perform a cleanup of feature data
 Delete invalid B-curves data (not a visible option; is performed automatically)
5. Select I n f o > A n a l y si s > Ex a m i n e Ge o m e t r y. The Examine Geometry features
allows users to analyze solid bodies, faces, and edges for detection of corrupt data struc-
tures and geometric anomalies. The system cannot automatically correct errors, but
highlights them to provide the user with an opportunity to correct them. If a body is
found to be invalid, further modeling or downstream operations (e.g., CAM, FEA, and
STEP) may fail. Click the Se t A l l Ch e ck s button and Se l e ct A l l to fully analyze the
geometry. Any errors returned in the bodies and faces sections must be repaired before
exporting to STEP. See the I n f o > A n a l y si s > Ex a m i n e Ge o m e t r y section at
www.cax-if.org/bestprac/stepbpg.htm for details. The Examine Geometry options are:
 Objects
— Tiny
— Misaligned
 Bodies
— Data Structures
— Consistency
— Face-Face Intersections
— Sheet Boundaries
 Faces
— Smoothness
— Self-Intersection
— Spikes/Cuts
 Edges
— Smoothness
— Tolerances
6. Import the STEP file back into Unigraphics for a “loop” test to verify that the solid model
data in the STEP file can be successfully re-created in Unigraphics.
After reviewing the error messages and making appropriate modifications the STEP files can be
exported to the STEP file for further processing.
N ot e : Unigraphics STEP files generated with a (U n i g r a p h i cs > ST EP ) Face/Edge B-

spline approximation tolerance value looser than the default of 0.0000000101 back
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into Unigraphics may generate solid validation faults with the resulting solid in
Unigraphics.
N ot e : For more, see STEP File Case Studies and Troubleshooting.
Healing Imported STEP Files
The AdvantEdge STEP File Import healing feature attempts to construct valid solid models by
repairing bad geometries in STEP files. Often, geometry problems in STEP files are due to
interoperability issues during translation, or insufficient geometric/topological file information.
The STEP healing feature generates this valid solid model based on the file’s user-defined healing
tolerance value (the size of the smallest feature retained in the STEP file). Reasonable values for
STEP healing tolerance range from 0.001 mm (1 micron) to 0.02 mm (20 microns). Values larger
than 20 microns may modify the geometry significantly, failing to create a valid solid model and
generate a volume mesh. In most cases, the default healing tolerance value of 0.001 mm
(1 micron) is sufficient. The smallest supported size is 0.0001 mm; if the user enters a value of
zero, 0.0015 mm (1.5 microns) will automatically be used.
N ot e : Users are advised to use the healing feature ONLY for cases where meshing fails.
Fi g u r e 8 - 2 9 : ST EP T o o l I m p o r t w i n d o w w i t h H e a l i n g f e a t u r e se l e ct e d
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Fi g u r e 8 - 3 0 : ST EP W o r k p i e ce I m p o r t w i n d o w w i t h H e a l i n g f e a t u r e se l e ct e d
For more information on generating meshes with imported STEP files, see STEP Analyzer.
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CHAPTER 9 — 2D PROCESS SETUP
9.1 — Turning/Sawing/Broaching
Using the Process Parameters window, users simulating turning, sawing, and broaching can enter
feed, surface speed, length of cut, depth of cut and initial temperature. Feed is in mm/rev
[0.001 in/rev] and cutting speed is in surface meters/min, smm [sfm]. To open the Process
Parameters window, select P r o ce ss > P r o ce ss P a r a m e t e r s.
N ot e : AdvantEdge assumes a plane strain condition; therefore, changing the depth of cut
will scale the force plots properly but will not change the contour plot results. It will
also not affect the simulation computation time.
Fi g u r e 9 - 1 : T u r n i n g P r o ce ss P a r a m e t e r s w i n d o w
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2 D Pr oce ss Se t u p | Up a n d D ow n M illin g
9.2 — Up and Down Milling

Using the Process Parameters window, users simulating up and down milling can enter spindle
speed, feed per tooth or feed per revolution (including teeth per cutter), radial width of cut, axial
depth of cut, initial temperature, and length of cut. To open the Process Parameters window, select
P r o ce ss > P r o ce ss P a r a m e t e r s.
N ot e : AdvantEdge will use radial width of cut – along with other parameters – to define
the workpiece length and chip shape.
Fi g u r e 9 - 2 : D o w n M i l l i n g P r o ce ss P a r a m e t e r s w i n d o w
9.3 — Friction Coefficient

The friction coefficient between the tool and workpiece can have significant effects on simulation
results. AdvantEdge uses a friction coefficient as defined by Coulomb friction in the following
equation:
F f =   Fn
Where F n is the normal force exerted between the surfaces,  is the coefficient of friction and F f is
the resulting force due to friction.
The user can define the friction coefficient by selecting P r o ce ss > Fr i ct i o n . The Friction
Coefficient window will appear and the user can activate either the D e f a u l t or U se r D e f i n e d
radio button. Selecting the User Defined radio button allows the user to manually enter the friction
coefficient. The friction coefficient is constrained by AdvantEdge to be between 0 and 1.
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2 D Pr oce ss Se t u p | Coola n t M ode lin g
Fi g u r e 9 - 3 : Fr i ct i o n Co e f f i ci e n t w i n d o w
9.4 — Coolant Modeling

Utilizing the AdvantEdge coolant modeling feature, users can simulate the effects of coolant for
both 2D and 3D cutting processes. To open the Coolant window, select P r o ce ss > Co o l a n t .
Fi g u r e 9 - 4 : Co o l a n t w i n d o w
Input the necessary heat transfer coefficient (h) and initial coolant temperature and select one of
the coolant area options:
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The values of heat transfer coefficients depend on the type of coolant used. Values for standard
coolants can be obtained from literature or obtained from experiments. Initial coolant temperature
usually corresponds to the room temperature.
Temperature Dependent Coolant
When utilizing Coolant Modeling, users have the ability to define a temperature dependent coolant
by selecting the T e m p e r a t u r e D e p e n d e n t P r o p e r t i e s radial bullet. The Temperature Input
Table window will open, allowing the user to input different heat transfer coefficients.
Fi g u r e 9 - 5 : T e m p e r a t u r e I n p u t T a b l e w i n d o w
Immersed Coolant
With the immersed coolant option of Coolant Modeling, heat flux due to coolant is applied to all
exposed and non-contacting surfaces on the tool and the workpiece, except the bottom face of the
workpiece and the faces on the tool where constant temperature boundary conditions are applied
(for more, see Set Boundary Conditions).
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Fi g u r e 9 - 6 : Co o l a n t w i n d o w w i t h I m m e r se d Co o l a n t o p t i o n se l e ct e d ; a r r o w s i n d i ca t e h e a t
f l u x b o u n d a r y co n d i t i o n
Excluded Tip Vicinity Coolant
When utilizing the excluded tip vicinity coolant option of the Coolant Modeling window, workpiece
surfaces within a specified distance from the tip vicinity are excluded from the heat flux boundary
condition due to coolant. This option can be used for cases where the coolant is blocked from
certain regions near the cutting edge due to factors such as excessive chip curl.
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Fi g u r e 9 - 7 : Co o l a n t w i n d o w w i t h Ex cl u d e d T i p V i ci n i t y Co o l a n t o p t i o n se l e ct e d ; a r r o w s
i n d i ca t e h e a t f l u x b o u n d a r y co n d i t i o n
Focused Coolant
With the focused coolant option of Coolant Modeling, AdvantEdge will simulate the effect of coolant
coming from a jet. Users must specify X, Y and Z coordinates of the coolant jet target location, as
well as the coolant jet radius. The heat flux boundary condition due to coolant is applied only in the
region specified at the given location.
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Fi g u r e 9 - 8 : Co o l a n t w i n d o w w i t h Fo cu se d Lo ca t i o n Co o l a n t o p t i o n se l e ct e d ; a r r o w s i n d i ca t e
h e a t f l u x b o u n d a r y co n d i t i o n
Focused Coolant: Model Pressure
With the focused coolant model pressure function of Coolant Modeling, users can study the effects
of coolant pressure on chip formation by modeling coolant as a traction boundary on the chip.
Coolant flow is assumed to be uniform and steady after leaving the nozzle, and jet velocity is not
reduced after hitting the chip. Unlike other Coolant Modeling selections, this modeling option
ignores the tool completely.
To use this capability, activate the Fo cu se d Lo ca t i o n radio button and check the M o d e l
P r e ssu r e checkbox. Specify the jet radius, nozzle location, jet angle, and jet velocity. The nozzle
location is defined using the bottom left-hand corner of the workpiece as the origin. The jet stream
angle is defined by a straight line extending from the nozzle, with a thickness equal to two times
the radius of the jet stream.
135
Fi g u r e 9 - 9 : Co o l a n t w i n d o w w i t h Fo cu se d Lo ca t i o n Co o l a n t o p t i o n se l e ct e d a l o n g w i t h M o d e l
P r e ssu r e f e a t u r e
M OD EL PRESSURE D I SPLAYED W I TH I N TH E AD VAN TED GE GUI
When the Model Pressure capability is selected, AdvantEdge will display a circle at the nozzle
location and a vector in the direction of the coolant. The bandwidth of the jet stream is not shown.
The user should verify that this location and direction are correct before running the simulation.
N ot e : To view the coolant directional vector, the 2D Graphical User Interface (GUI) Y-
value must be greater than the workpiece height.
136
2 D Pr oce ss Se t u p | Pr oce ss Opt ion s
Fi g u r e 9 - 1 0 : A d v a n t Ed g e GU I i n d i ca t i n g n o z z l e l o ca t i o n a n d j e t d i r e ct i o n
Within Tecplot, the user is able to view this contact region; for more, see Focused Location with
Model Pressure Coolant Display.
9.5 — Process Options

The Process Options Parameters window allows users to select between two cutting modes: general
(the default) and burr. The burr cutting mode automatically changes length of cut to the workpiece
length, plus 2 times the feed. This will cause a burr to form at the end of the workpiece after the
chip detaches. To open the Process Options Parameters window, select P r o ce ss > P r o ce ss
O p t i o n s.
137
CHAPTER 10 — 3D PROCESS SETUP
10.1 — Turning
Oblique and Nose Turning
Process parameters for both oblique turning and nose turning are the same, requiring a feed, depth
of cut (workpiece width in oblique turning), length of cut, cutting speed, and initial temperature.
Fi g u r e 1 0 - 1 : T u r n i n g P r o ce ss P a r a m e t e r s w i n d o w f o r o b l i q u e t u r n i n g
139
3 D Pr oce ss Se t u p | M illin g
OD and Face Turning
OD and face turning process parameters differ slightly from those of Oblique and Nose Turning,
since the tool is feeding along the radius as opposed to the axial direction. Users can specify a
constant rotational speed or a constant surface speed. A maximum rotational speed is specified in
the facing window.
Fi g u r e 1 0 - 2 : O D T u r n i n g P r o ce ss P a r a m e t e r s w i n d o w
10.2 — Milling
Side Cutting
For side cutting, the user must input standard milling parameters such as RPM, feed per tooth, and
axial depth of cut. Depth of cut will be specified as the height of the workpiece (for more, see Side
Cutting Workpieces).
140
Fi g u r e 1 0 - 3 : D o w n M i l l i n g P r o ce ss P a r a m e t e r s w i n d o w f o r si d e cu t t i n g
Corner Cutting
For corner cutting, the user must input standard milling parameters such as RPM, feed per tooth,
axial depth of cut, and depth of cut. Process parameters for a constant chip load corner cutting
simulation are the same, but a different picture will display during process setup.
Fi g u r e 1 0 - 4 : D o w n M i l l i n g P r o ce ss P a r a m e t e r s w i n d o w f o r co r n e r cu t t i n g
141
Face Milling
For face milling, users will enter spindle speed, feed per tooth, axial depth of cut, initial
temperature, and angular length of cut. Informationally, workpiece width can be smaller or larger
than the tool diameter, and depth of cut is determined by workpiece width. For more, see Face
Milling Workpieces and Milling Tools.
Fi g u r e 1 0 - 5 : Fa ce M i l l i n g P r o ce ss P a r a m e t e r s w i n d o w
Ramp Milling
For ramp milling, the workpiece has a component of velocity in the positive Z direction, in addition
to the velocity in the X direction. The Z velocity is determined from the ramp angle input by the
user.
142
Fi g u r e 1 0 - 6 : R a m p M i l l i n g P r o ce ss P a r a m e t e r s w i n d o w
Plunge Milling
Plunge milling is very similar to the Drilling process: the workpiece moves in the positive Z direction
while the tool rotates about the Z axis. A special solid tool with a cutting edge up to the center is
used for plunge milling; for more, see Milling Tools. Process parameters include spindle speed, feed
per tooth, and angular length of cut.
Fi g u r e 1 0 - 7 : P l u n g e M i l l i n g P r o ce ss P a r a m e t e r s w i n d o w
143
3 D Pr oce ss Se t u p | D r illin g
Pocket Milling
Pocket milling is simulated in AdvantEdge using the Corner Cutting configuration. Process
parameters include pocket length, pocket width, pocket corner angle, pocket corner radius, finish
stock, and axial depth of cut.
Fi g u r e 1 0 - 8 : P o ck e t M i l l i n g P r o ce ss P a r a m e t e r s w i n d o w
10.3 — Drilling
Each type of drilling process (entrance, starting depth, exit) contains unique process parameters.
For entrance drilling, users must input spindle speed, feed per revolution, initial temperature, and
angular length of cut. For starting depth drilling, a starting depth parameter is also required,
specifying how far into the cut the drill is at the simulation start. For exit drilling, a number of
revolutions to exit parameter is required.
144
3 D Pr oce ss Se t u p | Gr oovin g
Fi g u r e 1 0 - 9 : D r i l l i n g P r o ce ss P a r a m e t e r s - St a r t i n g D e p t h w i n d o w
10.4 — Grooving
Since grooving is a type of Turning process, the Grooving Process Parameters window is similar to
that of standard turning. The OD Grooving Process Parameters window is similar to that of OD and
Face Turning.
Fi g u r e 1 0 - 1 0 : Gr o o v i n g P r o ce ss P a r a m e t e r s w i n d o w
145
3 D Pr oce ss Se t u p | Bor in g
Fi g u r e 1 0 - 1 1 : O D Gr o o v i n g P r o ce ss P a r a m e t e r s w i n d o w
10.5 — Boring
For boring processes, necessary parameters include spindle speed, feed per revolution, initial
temperature, and angular length of cut.
Fi g u r e 1 0 - 1 2 : Bo r i n g P r o ce ss P a r a m e t e r s w i n d o w
146
3 D Pr oce ss Se t u p | Ta ppin g
10.6 — Tapping
Tapping process parameters are similar to Drilling, except that the feed is automatically calculated
based on the tap geometry (for more, see Tapping Tools). Required inputs include spindle speed,
initial temperature, and angle of rotation.
Fi g u r e 1 0 - 1 3 : T a p p i n g P r o ce ss P a r a m e t e r s w i n d o w
10.7 — Orbital Drilling

For all orbital drilling processes, users must input spindle speed, orbit speed, diameter offset, axial
feed rate, initial temperature, angle of tool rotation, and orbital direction.
147
3 D Pr oce ss Se t u p | Or bit a l D r illin g
Fi g u r e 1 0 - 1 4 : O r b i t a l D r i l l i n g P r o ce ss P a r a m e t e r s - En t r a n ce w i n d o w
In addition to these parameters, starting depth orbital drilling simulations require the user to define
the starting depth, which specifies how far into the cut the drill is at the simulation start.
Fi g u r e 1 0 - 1 5 : O r b i t a l D r i l l i n g P r o ce ss P a r a m e t e r s - St a r t i n g D e p t h w i n d o w
Similarly, exit orbital drilling simulations require the user to specify the number of revolutions to
exit the workpiece.
148
3 D Pr oce ss Se t u p | Pr oce ss Type w in dow s
Fi g u r e 1 0 - 1 6 : O r b i t a l D r i l l i n g P r o ce ss P a r a m e t e r s - Ex i t w i n d o w
10.8 — Process Type windows

Process Type windows are helpful when users have selected the wrong process type during initial
simulation setup. Instead of setting up an entirely new simulation, the process type can be changed
by selecting P r o ce ss > P r o ce ss T y p e s. For Milling simulations, this window allows users to
choose between up, down, 5-axis and constant chip load milling. For Drilling and Boring
simulations, this menu allow users choose between entrance, starting depth, and exit drilling.
Fi g u r e 1 0 - 1 7 : M i l l i n g P r o ce ss T y p e w i n d o w
Process parameters windows will automatically reflect the revised process type. For example, if the
user had originally established an up milling corner cutting simulation but switched to a 5-axis
down milling simulation, the Down Milling Process Parameters window would adjust to display 5-
axis down milling parameter requirements.
149
3 D Pr oce ss Se t u p | Fr ict ion Coe fficie n t
10.9 — Friction Coefficient

The friction coefficient between the tool and workpiece can have significant effects on simulation
results. AdvantEdge uses a friction coefficient as defined by Coulomb friction in the following
equation:
F f =   Fn
Where F n is the normal force exerted between the surfaces,  is the coefficient of friction and F f is
the resulting force due to friction.
The user can define the friction coefficient by selecting P r o ce ss > Fr i ct i o n . The Friction
Coefficient window will appear and the user can activate either the D e f a u l t or U se r D e f i n e d
radio button. Selecting the User Defined radio button allows the user to manually enter the friction
coefficient. The friction coefficient is constrained by AdvantEdge to be between 0 and 1.
Fi g u r e 1 0 - 1 8 : Fr i ct i o n Co e f f i ci e n t w i n d o w
10.10 — Coolant Modeling

The Coolant Modeling menu in AdvantEdge 3D offers the same opportunities as in AdvantEdge 2D.
10.11 — Process Options

The Process Options Parameters window allows users to select between two cutting modes: general
(the default) and burr. The burr cutting mode automatically changes length of cut to the workpiece
length, plus 2 times the feed. This will cause a burr to form at the end of the workpiece after the
chip detaches. To open the Process Options Parameters window, select P r o ce ss > P r o ce ss
O p t i o n s.
150
CHAPTER 11 — CUSTOM MATERIALS
The modeling capabilities of AdvantEdge allow users to import custom materials and/or input
necessary material properties. These custom materials may be mixed with standard materials for
easier use. A custom material can be used for the workpiece, tool, and/or coating(s).
The user must tell AdvantEdge each area where custom materials will be used by accessing the
individual setup windows and activating the Cu st o m radio button:
• Custom Workpiece Materials: W o r k p i e ce > W o r k p i e ce M a t e r i a l

• Custom Tool Materials: T o o l > T o o l M a t e r i a l
• Custom Tool Coatings materials: T o o l > Co a t i n g M a t e r i a l
*User must still enter a coating thickness
• Custom tool cutter body material: T o o l > Cu t t e r Bo d y M a t e r i a l
Tools and coatings are modeled only as elastic bodies and do not plastically deform. Therefore, to
model tool and coating materials, only heat transfer and elastic properties are needed. The
constitutive model options that follow, with the exception of the Temperature Dependant (TD)
Power Law, exclusively affect the plastic deformation of the material. If a temperature dependant
model is used, the user can also enter thermal conductivity, heat capacity, and thermal expansion
data that vary with temperature.
In order to apply one custom coating material, all coating materials must be custom-defined. For
example, if a user has one layer of TiN and is experimenting with a custom coating as a different
layer, the properties for both the TiN and coating must be entered or imported.
11.1 — Constitutive Model

Users must determine the constitutive model by which Custom Materials are to be governed, then
enter the required parameters. These parameters vary for every constitutive model, and
AdvantEdge will grey out any tabs or information not required for that specific model. All
constitutive models are accessible by selecting Cu st o m M a t e r i a l s > Co n st i t u t i v e M o d e l .
151
Cu st om M a t e r ia ls | Con st it u t ive M ode l
Power Law
p p
    ·  T  = g       ·     T 
p
where g    is Strain Hardening,   ·  is strain Rate Sensitivity and   T  is Thermal Softening.
P o w e r La w D a m a g e M o d e l ( 2 D o n l y ) — uses the power law but also includes a Damage

option for brittle materials.
P o w e r La w T E / P o w e r La w D a m a g e M o d e l T E — uses the standard power law and includes

a Thermal Expansion (TE) coefficient alpha. The thermal expansion coefficient will be taken into
account for residual stress simulations; otherwise, this model is unnecessary.
• 2D Residual Stress Analysis

P o w e r La w T D / P o w e r La w D a m a g e M o d e l T D — uses the standard power law and allows

the user to vary thermal Conductivity, Heat Capacity and Thermal Expansion as functions of
temperature (TD stands for temperature dependent). This model can be used to increase accuracy
of temperature and residual stress simulations.

N ot e : This model will increase overall simulation time and should only be used if
necessary.
P o w e r La w T D T a b l e / P o w e r La w D a m a g e M o d e l T D T a b l e — uses the standard power

law and also allows users to define the temperature dependence of thermal Conductivity and Heat
Capacity at various temperatures.
Drucker Prager
p p
    J 1 ·  T  = G    J 1     ·     T 
p
where G    J 1  is strain hardening plus hydrostatic pressure,   ·  is strain Rate Sensitivity and
  T  is Thermal Softening.
The strain hardening and hydrostatic pressure function can be broken down as follows:
p p
G    J 1  = g    + DP 0  J 1
p
where g    is Strain Hardening, DP 0 is the hydrostatic stress coefficient, and J 1 is the hydrostatic
pressure.
152
Cu st om M a t e r ia ls | H e a t Tr a n sfe r
p
The value of G    J 1  is limited by maximum tensile and compressive yield stresses, which are
called caps.
p p
If J 1  0 and G    J 1    maxtensile ,then G    J 1  =  maxtensile
p p
If J 1  0 and G    J 1    maxcompressive , then G    J 1  =  maxcompressive
Maximum tensile yield stress is:
 init
 maxtensile = -------------------
-
1 + DP 0
Maximum compressive yield stress is:
 init
 maxcompressive = -------------------
-
1 – DP 0
Here,  init is the initial yield stress.
D r u ck e r P r a g e r D a m a g e M o d e l — uses the Drucker Prager model with a Damage option for

brittle materials.
D r u ck e r P r a g e r T E / D r u ck e r P r a g e r D a m a g e M o d e l T E — uses the Drucker Prager model

and includes a Thermal Expansion (TE) coefficient alpha. The thermal expansion coefficient will be
taken into account for residual stress simulations; otherwise, this model is unnecessary.

N ot e : This model will increase overall simulation time and should only be used if
necessary.
User-Defined
The User-Defined Constitutive Model (2D Only) is for advanced users only and should be used only
when none of the existing models will suit the project needs.
11.2 — Heat Transfer

Heat transfer information for Custom Materials can be entered within the Workpiece Material
window. To open the Workpiece Material window for the custom material being defined, select
Cu st o m M a t e r i a l > W o r k p i e ce M a t e r i a l > M a t e r i a l “ X ”.
153
Cu st om M a t e r ia ls | St r a in H a r de n in g
Fi g u r e 1 1 - 1 : H e a t T r a n sf e r t a b o f W o r k p i e ce M a t e r i a l w i n d o w ; a l p h a i n p u t i s u n i q u e t o T D /
T E co n st i t u e n t m o d e l s
Within the Heat Transfer tab of the Workpiece Material window, the following information may be
entered:
• T h e r m a l Co n d u ct i v i t y — in W/m°C (Btu/h.ft.°F)
• H e a t Ca p a ci t y — in J/Kg°C (Btu/lb.°F)
• D e n si t y — in Kg/m3 (lb/ft3)
• A l p h a (the coefficient of thermal expansion) — in 1/°C (1/°F)
Repeat for each custom material as necessary.
11.3 — Strain Hardening

p
For Custom Materials, the strain hardening function g    for both the Power Law and Drucker
Prager is defined as:
154
Cu st om M a t e r ia ls | St r a in H a r de n in g
 p 1n
p   p p
g    =  0  1 + ----- , if    cut
 0 
p
p 1n
p   cut p p
g    =  0  1 + -------- , if    cut
 0 
p
p p p
where  0 is the initial yield stress,  is the plastic strain,  0 is the reference plastic strain,  cut is
the cut off strain, and 1  n is the strain hardening exponent.
Fi g u r e 1 1 - 2 : Sa m p l e st r a i n h a r d e n i n g cu r v e n o r m a l i z e d t o i n i t i a l y i e l d st r e ss
Strain hardening information can be entered within the Workpiece Material window. To open the
Workpiece Material window for the custom material being defined, select Cu st o m M a t e r i a l >
W o r k p i e ce M a t e r i a l > M a t e r i a l “ X ”.
155
Cu st om M a t e r ia ls | Th e r m a l Soft e n in g
Fi g u r e 1 1 - 3 : St r a i n H a r d e n i n g t a b o f W o r k p i e ce M a t e r i a l w i n d o w
Within the Strain Hardening tab of the Workpiece Material window, the following information may
be entered:
• Si g m a 0 [ sg 0 ] (initial yield stress) — in Pa (psi)

• R e f e r e n ce p l a st i c st r a i n [ e p 0 ] — strain corresponding to the initial yield stress
• St r a i n h a r d e n i n g e x p o n e n t [ e p n ] — decreases with increasing strain hardening depen-
dence
• Ep s Cu t o f f [ e p c] — used to limit the strain hardening function. After the cut off strain has
been exceeded, the model becomes perfectly plastic with constant flow stress. This prevents
large extrapolation errors at strains that are higher than tested.
The Gr a p h button displays the exponential relationship between the stress and strain variables.
11.4 — Thermal Softening

For Custom Materials, the thermal softening function   T  for both the Power Law and Drucker
Prager is defined as:
1 2 3 4 5
  T  = c0 + c1 T + c2 T + c3 T + c4 T + c5 T , if T  T cut
T – T cut 
  T  =   T cut   1 – ----------------------------
- , if T  T cut
 T –T 
melt cut
156
Cu st om M a t e r ia ls | Ra t e Se n sit ivit y
where c 0 through c 5 are coefficients for the polynomial fit, T is the temperature, T cut is the linear
cut off temperature, and T melt is the melting temperature.
Fi g u r e 1 1 - 4 : Sa m p l e t h e r m a l so f t e n i n g cu r v e n o r m a l i z e d t o i n i t i a l y i e l d st r e ss
Thermal softening information can be entered within the Workpiece Material window. To open the
W o r k p i e ce M a t e r i a l > M a t e r i a l “ X ” .
Within the Thermal Softening tab of the Workpiece Material window, the following information may
be entered:
• C0 [ c0 ] – C5 [ c5 ] — the polynomial coefficients for fitting a 5-order polynomial. For

lower-order polynomials, set the remaining C variables to zero.
• R e f e r e n ce T e m p e r a t u r e [ T r ] — units are °C (°F)
• M e l t T e m p e r a t u r e [ T m ] — the temperature at which either the material melts or the
yield stress is zero. Units are °C (°F).
• Cu t O f f T e m p e r a t u r e [ T c] — the temperature at which the yield stress is linearly soft-
ened until the yield strength is zero. Units are °C (°F).
The Gr a p h button displays the fifth-order polynomial defined by the above coefficients (c0–c5).
11.5 — Rate Sensitivity

For Custom Materials, the rate sensitivity function   ·  for both the Power Law and Drucker Prager
is defined as:
157
Cu st om M a t e r ia ls | Ra t e Se n sit ivit y
1
------
· m
 1
  ·  =  1 + ----
- , if 
·  ·
 · 0 t
1 1 1
------
m2 
- – ------
· -----
·
 t  m1 m2
  ·  =  1 + -----  1 + ----
- , if 
· 
 ·   
· t
0 0
·
where · is strain rate, · 0 is reference plastic strain rate,  t is strain rate where the transition
between low and high strain rate sensitivity occurs, m 1 is the low strain rate sensitivity coefficient,
and m 2 is the high strain rate sensitivity coefficient.
Fi g u r e 1 1 - 5 : Sa m p l e r a t e se n si t i v i t y cu r v e n o r m a l i z e d t o i n i t i a l y i e l d st r e ss
Rate sensitivity information can be entered within the Workpiece Material window. To open the
158
Cu st om M a t e r ia ls | Ela st ic
Fi g u r e 1 1 - 6 : R a t e Se n si t i v i t y t a b o f W o r k p i e ce M a t e r i a l w i n d o w
Within the Rate Sensitivity tab of the Workpiece Material window, the following information may be
entered:
• Lo w r a t e e x p o n e n t [ m 1 ] — the low strain rate sensitivity coefficient. Typically has values

between 20 and 200.
• H i g h r a t e e x p o n e n t [ m 2 ] — the high strain rate sensitivity coefficient. Typically has val-
ues between 20 and 200.
• EP SP D O T [ e p r ] — the reference plastic strain rate. Has units of 1/sec.
• EP SP T D O T [ e p t ] — the threshold strain rate where the transition between load and high
strain rate sensitivity occurs. Has units of 1/sec.
The Gr a p h button displays the exponential relationship between flow stress and strain rate.
11.6 — Elastic
For Custom Materials, elastic variables are used to compute stress in the elastic strain region until
the yield stress is reached and plastic deformation begins.
Elastic information can be entered within the Workpiece Material window. To open the Workpiece
Material window for the custom material being defined, select Cu st o m M a t e r i a l > W o r k p i e ce
M a t e r i a l > M a t e r i a l “ X ”.
159
Cu st om M a t e r ia ls | D a m a ge
Fi g u r e 1 1 - 7 : El a st i c t a b o f W o r k p i e ce M a t e r i a l w i n d o w
Within the Elastic tab of the Workpiece Material window, the following information may be entered:
• Y o u n g ’ s M o d u l u s [ Ey ] — used to describe the stress strain relationship during elastic

deformation. Units are Pa (psi).
• P o i sso n ’ s R a t i o [ P r ]
11.7 — Damage
When defining Custom Materials, the damage function D is represented by the following equation:
p

D =  --------i-
p
i f
i
p
where D is the dimensionless cumulative damage,  i is the instantaneous increment of strain,
p
and  f is the instantaneous strain to failure.
i
Damage information can be entered within the Workpiece Material window. To open the Workpiece
Material window for the custom material being defined, select Cu st o m M a t e r i a l > W o r k p i e ce
M a t e r i a l > M a t e r i a l “ X ”.
160
Fi g u r e 1 1 - 8 : D a m a g e t a b o f W o r k p i e ce M a t e r i a l w i n d o w
Within the Damage tab of the Workpiece Material window, the following information may be
entered:
• D 0 [ d 0 ] – D 5 [ d 5 ] — The damage model consists of a curve fit to a Strain to Failure vs

Temperature graph. This curve fit can be up to a 5-order polynomial. These coefficients
define the strain to failure using the following equation:
p 1 2 3 4 5
 f 0 = d 0 + d 1T + d 2T + d 3T + d 4T + d 5T
AdvantEdge stores all strain data as tensile strain data. Compression data is converted to tensile
data for storage using the following equation:
p
p  C0
 t0 = ----------------------------
-
exp  3Cp 
p p
where  f 0 is the strain to failure compression polynomial, Cp is the pressure coefficient, and  t0 is
the equivalent strain to failure tensile polynomial. Tensile strain data input is left unchanged.
161
Fi g u r e 1 1 - 9 : Sa m p l e st r a i n t o f a i l u r e cu r v e f o r b r i t t l e m a t e r i a l
• D a m a g e Cu t o f f T e m p e r a t u r e [ T c( D A M ) ] — Units are °C (°F). Materials tend to

exhibit increased ductility at higher temperature and potentially become quite ductile. To
account for this phenomenon, a damage cut off parameter is defined to indicate the onset of
high ductility where no further damage accumulates.
• Fa i l u r e St r a i n I n cr e m e n t [ EP SD ELT A ] — After an element has reached the strain to
failure limit (imposed by the damage model), the element progressively loses its strength
over a defined amount of additional strain.
• P r e ssu r e Co e f f i ci e n t [ Cp ] — Materials exhibit very different ductility in tension as com-
pared to compression. The following is the Strain to Failure equation that modifies initial
strain to failure based on pressure:
– 1.5  c p  J 1 p
 = b  exp  ---------------------------------- 
   f0
p
where  f is the strain to failure at the current state of stress,
3c
b is defined as exp  ------------------p- ,
 2 
p
c p is the pressure dependency coefficient, J 1 is the hydrostatic pressure,  is     ·  T  for Power
p p
Law models or     J 1 ·  T  for Drucker Prager models, and  f 0 is the temperature dependent strain
to failure determined using the initial polynomial equation.
• P r e ssu r e Co e f f i ci e n t — used to distinguish the difference between failure in tension and

failure in compression. This constant can be found using the strain to failure values at room
temperature for both compression and tension in the following formula:
p
1  
c p = ------- ln  ----c-
3   tp
162
Cu st om M a t e r ia ls | Con du ct ivit y
p p
Where  c is the strain to failure in compression,  t is the strain to failure in tension, and c p is the
pressure coefficient.
• D a m a g e Cu t O f f St r a i n [ EP Sc( D A M ) ] — defines the threshold strain after which no

more damage accumulates. Default value is 3.
• D a m a g e M o d e l T y p e — identifies the type of data used to create the curve fit. Strain to
failure data can come from either tension or compression data.
11.8 — Conductivity
When defining Custom Materials, the Conductivity tab will only appear for the temperature
dependent constitutive models such as the Power Law TD and Power Law Damage TD. The thermal
conductivity function K  T  is described by the following stepwise function:
K T  1 2 3 4 5
K   K 0 + K 1 T + K 2 T + K 3 T + K 4 T + K 5 T  T ref  T  T ma
= K  T ref  T  T ref
= K  T max  T  T max
where K 0 through K 5 are coefficients for the polynomial fit, T is the temperature, T max is the linear
cut off temperature, T ref is the reference temperature, and K is the baseline thermal conductivity.
The stepwise function states that when the temperature is above the reference temperature and
below the maximum temperature, the thermal conductivity will vary depending on temperature.
Fi g u r e 1 1 - 1 0 : Gr a p h sh o w i n g r e l a t i o n sh i p b e t w e e n t h e r m a l co n d u ct i v i t y a n d t e m p e r a t u r e
Conductivity information can be entered within the Workpiece Material window. To open the
163
Cu st om M a t e r ia ls | H e a t Ca pa cit y
Fi g u r e 1 1 - 1 1 : Co n d u ct i v i t y t a b o f W o r k p i e ce M a t e r i a l w i n d o w
Within the Conductivity tab of the Workpiece Material window, the following information may be
entered:
• K0 t h r o u g h K5 — the polynomial coefficients for fitting a fifth order polynomial. For lower
order polynomials, set the remaining coefficients to zero. For example, for a fourth order
polynomial, K5 would equal zero.
• T r e f ( K r e f ) — the reference temperature. When the temperature is below this tempera-
ture, the thermal conductivity is held constant at K (T ref). The units are °C (°F).
• T m a x ( K m a x ) — the maximum temperature. Above this temperature the thermal con-
ductivity is held constant at K (T max). The units are °C (°F).
A ratio is created from the coefficients (k0 through k5), and this ratio varies with temperature. To
obtain the conductivity at a specific temperature, multiple the ratio by the baseline thermal
conductivity [k], which is displayed within the Heat Transfer tab. When this ratio equals 1, the
thermal conductivity is equivalent to the baseline thermal conductivity.
Repeat this process for each custom material as necessary.
N ot e : For more, see Temperature Dependent Constitutive Models: Relating Conductivity

to Heat Transfer.
11.9 — Heat Capacity

When defining Custom Materials, the heat capacity function C( T) is for the Power Law TD and Power
Law Damage Model TD constitutive models and is described by the following polynomial function:
164
Cu st om M a t e r ia ls | H e a t Ca pa cit y
 2 3 4 5
c  C p 0 + C p 1 T + C p 2 T + C p 3 T + C p 4 T + C p 5 T  C pref  T  C pmax


T  =  cC p + C p C 2 3 4 5
0 1 pref + C p 2  C pref  + C p 3  C pref  + C p 4  C pref  + C p 5  C pref   T  C pref

cC p + C p C 2 3 4
 0 1 pmax + C p 2  C pmax  + C p 3  C pmax  + C p 4  C pmax  + C p 5  C pmax   T  C pma
where c is the heat capacity entered in the Heat Transfer tab of the Workpiece Material window, Cp 0
through C p 5 are coefficients from a polynomial fit, T is the temperature and C max is the linear cut
off temperature.
Heat capacity information can be entered within the Workpiece Material window. To open the
Fi g u r e 1 1 - 1 2 : H e a t Ca p a ci t y t a b o f W o r k p i e ce M a t e r i a l w i n d o w
Within the Heat Capacity tab of the Workpiece Material window, the following information may be
entered:
• Cp 0 [ cp 0 ] – Cp 5 [ cp 5 ] — the polynomial coefficients obtained from fitting a 5th-order

polynomial to a plot of heat capacity versus temperature between the temperature range
cpref (<=) T (<=) cpm ax . For lower-order polynomials, set the remaining Cp coefficients to
zero.
• Cp r e f [ cp r e f ] — the reference temperature. Units are °C (°F).
• Cp m a x [ cp m a x ] — Units are °C (°F). At this temperature and above the heat capacity is
held constant.
165
Cu st om M a t e r ia ls | Th e r m a l Ex pa n sion
11.10 — Thermal Expansion

When defining Custom Materials, the thermal expansion function   T  is for the Power Law TD and
Power Law Damage TD constitutive models and is described by the following polynomial function:
 2 3 4 5
  a 0 + a 1 T = a 2 T + a 3 T + a4T + a 5 T  A ref  T  A max


  T  =    a + a A + a  A  2 + a  A  3 + a  A  4 + a  A  5  T  A
0 1 ref 2 ref 3 ref 4 ref 5 ref ref

a + a A 2 3 4 5
 0 1 max + a 2  A max  + a 3  A max  + a 4  A max  + a 5  A max   T  A max
where Alpha (  ) is the thermal expansion coefficient entered in the Heat Transfer tab, a 0 through
a 5 are coefficients from a polynomial fit, T is the temperature and A max is the linear cut off
temperature.
Thermal expansion information can be entered within the Workpiece Material window. To open the
Fi g u r e 1 1 - 1 3 : T h e r m a l Ex p a n si o n t a b o f W o r k p i e ce M a t e r i a l w i n d o w
Within the Thermal Expansion tab of the Workpiece Material window, the following information may
be entered:
• A 0 [ a 0 ] – A 5 [ a 5 ] — the polynomial coefficients obtained from fitting a fifth-order polyno-

mial to a plot of thermal expansion coefficient versus temperature between the temperature
range Aref (<=) T (<=) Am ax . For lower-order polynomials set the remaining A coefficients to
zero.
• A r e f [ a r e f ] — the reference temperature. Units are °C (°F).
166
Cu st om M a t e r ia ls | Te m pe r a t u r e D e pe n de n t ( TD ) Ta ble
• A m a x [ a m a x ] — Units are °C (°F). At this temperature and above, thermal expansion is

held constant.
11.11 — Temperature Dependent (TD) Table

When defining Custom Materials, the temperature dependent (TD) table feature is available with
Power Law, Power Law Damage Model and User-Defined Yield Surface Constitutive Model models,
and allows users to define the temperature dependence of thermal Conductivity and Heat Capacity
at various temperatures in table format. To open the Custom Material window for the custom
material being defined, select Cu st o m M a t e r i a l > W o r k p i e ce M a t e r i a l > M a t e r i a l “ X ”.
Fi g u r e 1 1 - 1 4 : Co n d u ct i v i t y t a b o f Cu st o m M a t e r i a l w i n d o w
Within the Conductivity and Heat Capacity tabs of the Custom Material Window, each TD property
can be defined as a table of data points, temperature being the variable and the property value the
dependent.
For example, TD thermal conductivity can be defined as
 T i K i  i = 1 2N
where K i denotes the conductivity at temperature T i , and N the number of data points.
For T m  T  T m + 1 , the conductivity at T is linearly interpolated as follows:
T – Tm
-K
K = K m + --------------------------- – K m .
Tm + 1 + Tm m + 1
For T  T 1 , K = K 1 . For T  T N , K + K N .
167
Cu st om M a t e r ia ls | D r u ck e r Pr a ge r
11.12 — Drucker Prager

When defining Custom Materials, Drucker Prager model-specific information can be entered within
the Workpiece Material window. To open the Workpiece Material window for the custom material
being defined, select Cu st o m M a t e r i a l > W o r k p i e ce M a t e r i a l > M a t e r i a l “ X ”.
Fi g u r e 1 1 - 1 5 : D r u ck e r P r a g e r t a b o f W o r k p i e ce M a t e r i a l w i n d o w
Within the Drucker Prager tab of the Workpiece Material window, the following information may be
entered:
• H y d r o st a t i c St r e ss Co e f f i ci e n t [ d p 0 ] — determines the hydrostatic stress sensitivity

to the yield stress.
11.13 — User-Defined Constitutive Model (2D Only)

To provide more flexibility with constitutive models, AdvantEdge 2D allows users to compile their
own dynamic link libraries. Dynamic link libraries are loaded by AdvantEdge 2D at execution. One of
these libraries describes the user-defined constitutive model. The user can compile their own
dynamic link library and replace the default library, if desired. This capability is only available for 2D
simulations; for those running 3D simulations, see User-Defined Yield Surface Constitutive Model.
N ot e : In Linux these dynamic libraries are called “shared libraries” or “plug ins.”
168
Cu st om M a t e r ia ls | Use r - D e fin e d Con st it u t ive M ode l ( 2 D On ly)
AdvantEdge 2D supports user-defined material models by providing an interface subroutine named

mat_user.f. In this subroutine, users can implement a customized constitutive model to update
stresses and other state variables. Once this subroutine is edited it should be compiled as a
dynamic link library (*.dll) to link to the AdvantEdge execution.
Given certain deformation measures, the subroutine calculates the stress response of the material
and returns the Cauchy stress to AdvantEdge 2D. Both rate formulation and total formulation are
supported. The engine passes both the rate of deformation D and the total deformation gradient F
to mat_user and users can choose either one to implement hypo- or hyperelasto-plastic constitutive
models.
• User-Defined Material Rate Formulation Example

• User-Defined Material Total Formulation Example
In addition to stress update, users can define up to 100 state variables, such as plastic strains and
hardening parameters, for each Gauss point. These variables are stored in a double precision array
of 100 components, real*8 user_s(100), which is passed to the subroutine as an argument. It is the
user’s responsibility to keep these state variables updated.
There are some state variables that exist within the model that are reserved. These are called
engine state variables and are labeled engine_s(*). The following four engine state variables must
be updated as the material deforms:
engine_s(1) plastic strain

engine_s(3) plastic work rate
engine_s(4) plastic strain rate
engine_s(5) damage
All these variables are passed in as double precision array argument. The engine uses these
variables for processes defined outside of the user-defined material, so it is essential that the
values are updated.
AdvantEdge 2D also allows the user to define up to 50 material parameters, which are stored in a
double precision array real*8 d(25:74). The other 50 parameters are reserved d(1:24) and d(75:100).
User may refer to the following parameters, but should not modify them.
d(5) lambda (Lame’s constant)

d(6) μ (Lame’s constant)
N ot e : For more, see Stress Update Formulations.
State Variable Initialization
When applying a User-Defined Constitutive Model (2D Only), some material state variables need to
be properly initialized. In this case, the current physical time, variable time, is passed on to the
subroutine mat_user. Based on the argument, users can choose to initialize the state variables.
169
Graphical User Interface (GUI)
Users can utilize up to 50 parameters to input user-defined material properties. These parameters
govern the material behavior and can be input using the 2D Graphical User Interface (GUI)
provided by AdvantEdge 2D. The variables UMATPAR01 to UMATPAR75 are transferred to the subroutine
mat_user as double precision d(25) to d(74) array.
To utilize the User-Defined Constitutive Model (2D Only):
1.Select W o r k p i e ce > W o r k p i e ce M a t e r i a l and activate the Cu st o m radio button

2.Select Cu st o m M a t e r i a l > Co n st i t u t i v e M o d e l > U se r D e f i n e d
3.Select Cu st o m M a t e r i a l s > W o r k p i e ce M a t e r i a l > M a t e r i a l 1 and enter the user-
defined parameters within the Custom Material window
Fi g u r e 1 1 - 1 6 : U se r D e f i n e d P a r a m e t e r t a b o f Cu st o m M a t e r i a l w i n d o w w i t h U se r D e f i n e d
Pa r a m e t e r w in dow ope n
In the user-defined sample model contained within the GUI, initial yield stress is referred to as
d(25).
N ot e : UMATPAR01 parameter refers to the d(25) array.
Input File Format
When creating a User-Defined Constitutive Model (2D Only), material parameters are specified in
the projectname_wp.twm file. The AdvantEdge 2D engine will then output the user-defined state
variables in the project.tec file for visualization.
170
PROJECTN AM E_ W P.TW M FI LE
Within the projectname_up.twm file, the following variables are reserved because they are used
outside the user-defined material routine:
• Young
• Poisson
• Conductivity
• Heat cap
• Density
These variables are part of the system material property parameters d(1:24) and d(75:100). The
variables UMATPAR01 to UMATPAR50 are assigned to the user-defined material parameters d(25:74).
The user can use the variable to transfer material properties from the projectname_wp.twm file to the
user-defined material routine. These variables remain constant throughout the execution.
Proj ect nam e_wp.t wm Exam ple
MODELTYPE=USER-DEFINED-MATERIAL
YOUNG=7.0E10
POISSON=3.0E-1
CONDUCTIVITY=1.0E2
HEATCAP=7.0E2
DENSITY=2.8E3
NUM_PARAM=1.0E1
%Variable_Name1=Initial Yield Stress
UMATPAR01=4.0E8
%Variable_Name2=Var-Name
UMATPAR02=0
UMATPAR03=0
UMATPAR04=0
UMATPAR05=0
UMATPAR06=0
UMATPAR07=0
UMATPAR08=0
UMATPAR09=0
UMATPAR10=0
MTLFILENAME=CustomMaterial001
171
Tecplot Output
When utilizing a User-Defined Constitutive Model (2D Only), the variables user_s(1:5) allow users to
visualize user-defined variables within Tecplot. The user-defined example provided within the
software sets user_s(1) equal to engine_s(1). This will allow the user to view the contour plot for the
engine state variable 1 (plastic strain) by selecting the user_s(1) variable within Tecplot.
To display these variables within Tecplot, the user must change the contour variable to
user_s(1,2,3,4,or 5). For example, a user could select user_s(1) to display the plastic strain
contours. To open the Contour Details window, double click on the Contour Legend. Once this
window appears, select the variable to display from the dropdown menu.
Fi g u r e 1 1 - 1 7 : Co n t o u r D e t a i l s w i n d o w
Dynamic Link Library Compilation
W I N D OW S XP
UserMat.dll is the compiled User-Defined Constitutive Model (2D Only). The library must be
compiled with Intel Fortran version 11.1 or higher. If users do not compile their own libraries,
AdvantEdge will use the sample provided with the software.
Windows syst em requirem ent s
• Windows XP/Windows 7 32 bit or 64 bit

• AdvantEdge 2D or 3D
172
• Intel Visual Fortran 11.1 or higher

• Microsoft Visual C++ .Net Standard
Procedure for Windows XP
1.Open Build Environment for Fortran IA-32 application DOS prompt by selecting St a r t > A l l
P r o g r a m s > I n t e l So f t w a r e D e v e l o p m e n t T o o l s > I n t e l FO R T R A N Co m p i l e r
> Bu i l d En v i r o n m e n t f o r Fo r t r a n I A - 3 2 a p p l i ca t i o n s
2.Wait for the following DOS prompt to appear:
Fi g u r e 1 1 - 1 8 : M S- D O S p r o m p t f o r co m p i l i n g i n Fo r t r a n
3.Compile “mat_user.f” using the following command:

ifort /DLL /libs:static /threads mat_user.f
4.Rename mat_user.dll to UserMat.dll
>rename mat_user.dll UserMat.dll
5.Overwrite UserMat.dll within
C:\ThirdWaveSystems\AdvantEdge\advanteng\bin\UserMat.dll
6.Set up user-defined material parameters using the AdvantEdge GUI and Sa v e the file
7.Su b m i t the job
User-Defined Material Rate Formulation Example
When creating a User-Defined Constitutive Model (2D Only), the mat_user.f file is compiled to
generate a custom UserMat.dll file. The AdvantEdge 2D engine uses this *.dll file to calculate the
material state.
Users will be required to compute Cauchy stress sig(3,3) based on [rate-of-deformation] x [time
increment] deps(3,3) or [deformation gradient] eps(3,3).
173
Material parameters d(25:74) will be read from the projectname_wp.twm file. For example,
UMATPAR01=0.1 in the projectname_wp.twm file will give a value of 0.1 to material parameter d(25). All
the values of the d(*) array are constant throughout the simulation.
USER_ M AT.F RATE FORM ULATI ON EXAM PLE
The following example shows implementation of an elastic, perfectly plastic material (no hardening)
using radial return algorithm. This AdvantEdge 2D user-defined material model is based on the
Jaumann rate formulation. deps is [ rat e of deform at ion] x [ t im e increm ent s] , sig is Cauchy stress,
and temp is temperature.
cccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccc
c
SUBROUTINE MAT_USER(d,time,dtime,temp,engine_s,user_s,
1 eps,deps,sig,df,kTimeStep)
c
c
c AdvantEdge 2D/3D User defined material
c Rate formulation example
c
c COPYRIGHT Third Wave Systems Inc. 2013
c www.thirdwavesys.com
c
c
c
c
#ifndef linux
!DEC$ ATTRIBUTES DLLEXPORT :: MAT_USER
#endif
implicit real*8 (a-h,o-z)
c
c sig(3,3) Previous and updated stress [Pa]
c sig(1,1) = Sxx, sig(2,2)=Syy, sig(1,2)=Sxy
c dtime time step [s]
c temp temperature [c]
c
c engine_s(1) Plastic strain [1]
c engine_s(3) Plastic work rate (heat generation) [w]
c engine_s(4) Plastic strain rate [1/s]
c engine_s(5) Damage
c engine_s(6:15) Engine state variables
c
c user_s(1:100) User state variable
c user_s(1:5) Tecplot output with “user”
c
c deps(3,3) Deformation tensor * dtime (strain increment)
c deps(1,1) = Dxx*dtime, deps(1,2)=Dxy*dtime,
deps(2,2)=Dyy*dtime
c
c eps(3,3) Total Deformation gradient
c
174
c
c df(3,3) Relative Deformation gradient
c
c
c Material properties are read from _wp.twm file
c
c Reserved material parameters
c d(5) lambda (Lame’s constant)
c d(6) mu (Lame’s constant)
c d(98) Conductivity
c d(99) Specific Heat * Density
c d(100) Density
c User defined material parameters

c d(25) UMATPAR01
c d(26) UMATPAR02
c d(27) UMATPAR03
c d(28) UMATPAR04
c d(29) UMATPAR05
c d(30) UMATPAR06
c d(31) UMATPAR07
c d(32) UMATPAR08
c d(33) UMATPAR09
c d(34) UMATPAR10
c d(35) UMATPAR11
c d(36) UMATPAR12
c d(37) UMATPAR13
c d(38) UMATPAR14
c d(39) UMATPAR15
c d(40) UMATPAR16
c d(41) UMATPAR17
c d(42) UMATPAR18
c d(43) UMATPAR19
c d(44) UMATPAR20
c d(45) UMATPAR21
c d(46) UMATPAR22
c d(47) UMATPAR23
c d(48) UMATPAR24
c d(49) UMATPAR25
c d(50) UMATPAR26
c d(51) UMATPAR27
c d(52) UMATPAR28
c d(53) UMATPAR29
c d(54) UMATPAR30
c d(55) UMATPAR31
c d(56) UMATPAR32
c d(57) UMATPAR33
c d(58) UMATPAR34
c d(59) UMATPAR35
c d(60) UMATPAR36
c d(61) UMATPAR37
175
c d(62) UMATPAR38
c d(63) UMATPAR39
c d(64) UMATPAR40
c d(65) UMATPAR41
c d(66) UMATPAR42
c d(67) UMATPAR43
c d(68) UMATPAR44
c d(69) UMATPAR45
c d(70) UMATPAR46
c d(71) UMATPAR47
c d(72) UMATPAR48
c d(73) UMATPAR49
c d(74) UMATPAR50
c
c
real*8 dtime,temp,d(100),engine_s(15),user_s(100),
eps(3,3), & deps(3,3),sig(3,3)
real*8 sigtr(3,3),q(3,3),dsig(3,3),sigdiv(3,3)
c
c
c Initialize state variable
c
if ( kTimeStep .eq. 1 )then

! if ( time .le. dtime )then
! write(6,’(‘’user_mat rate formulation’’)’)
engine_s(1:15)=0.0d0
user_s(1:100)= 0.0d0
end if
c write(6,*),” User material”
c do i=1,100
c write(6,*),i,d(i)
c enddo
c engine_s(5)=temp
c
dLambda = d(5)
d2mu = d(6)*2.0d0
d1mu = d(6)
c
c Hardening coefficient
c
dH = 0.0d0
c
c initialize plastic strain increment
deltaLamTotal = 0.0d0
c Initialize plastic strain rate
engine_s(4)=0.0d0
c Initialize plastic work (heat generation)
engine_s(3)= 0.0d0
176
c Elastic stress increment

tm1 = dLambda*(deps(1,1)+deps(2,2)+deps(3,3))
sigtr(1,1) = sig(1,1) + d2mu*deps(1,1)+tm1
c
sigtr(1,2) = sig(1,2) + d2mu*deps(1,2)
sigtr(2,1) = sigtr(1,2)
i=0
50 continue
c
c goto 110
c Calculate Deviatoric stress
call umat_div_stress(sigtr,sigdiv)
c Calculate deviatoric stress norm
sigma_e = umat_sigdiv_norm(sigdiv)
c Yield stress
yield = d(25)+ (1.0d0 + dH * engine_s(1) )
c Strain increment (Radial return method)
deltaLam =(sigma_e-dsqrt(2.0d0/3.0d0)*yield)/d2mu
1 /(1.0d0+dH/(3.0d0*d1mu))
c
c i=i+1
c write(6,*),”sigma i”,i,dsqrt(1.5d0)*sigma_e
c
if (deltaLam.le.0.0d0 .or. deltaLam.lt.1.0e-12) goto 100
c Case of plasticity
factor = 1.0d0/sigma_e
c
q(1,1)= factor*sigdiv(1,1)
c
deltaLamTotal = deltaLamTotal+deltaLam
c
c write(6,*),i,sigma_e,yield,deltaLam,deltaLamTotal
c
c Updated stress
c
sig(1,1) = sigtr(1,1)-deltaLam*d2mu*q(1,1)
177
c
sigtr(1,1)=sig(1,1)
sigtr(1,2)=sig(1,2)
sigtr(1,3)=sig(1,3)
sigtr(2,1)=sig(2,1)
sigtr(2,2)=sig(2,2)
sigtr(2,3)=sig(2,3)
sigtr(3,1)=sig(3,1)
sigtr(3,2)=sig(3,2)
sigtr(3,3)=sig(3,3)
c
goto 50
c
100 continue
c Plastic strain
engine_s(1)=engine_s(1)+deltaLamTotal
c
c Plastic strain rate
engine_s(4)=deltaLamTotal/dtime
c
c Plastic work rate (heat generation)
engine_s(3)=deltaLamTotal*YIELD/dtime
c write(6,*),”ql”,engine_s(1),engine_s(4),engine_s(3)
c Updated stress
110 continue
sig(1,1) = sigtr(1,1)
sig(1,2) = sigtr(1,2)
sig(1,3) = sigtr(1,3)
sig(2,1) = sigtr(2,1)
sig(2,2) = sigtr(2,2)
sig(2,3) = sigtr(2,3)
sig(3,1) = sigtr(3,1)
sig(3,2) = sigtr(3,2)
sig(3,3) = sigtr(3,3)
c
END SUBROUTINE
c
double precision function umat_sigdiv_norm(sigdiv)
c
c
real*8 sigdiv(3,3)
real*8 sigma_norm
178
c
sigma_norm = sigdiv(1,1)*sigdiv(1,1)
1 +sigdiv(2,2)*sigdiv(2,2)
1 +2.0d0*sigdiv(1,2)*sigdiv(1,2)
umat_sigdiv_norm = dsqrt(sigma_norm)
return
end
c
SUBROUTINE umat_div_stress(sig,sigdiv)
c
c Calculate Deviatoric stress
c
real*8 sigdiv(3,3),sig(3,3),pressure
pressure = (sig(1,1)+sig(2,2)+sig(3,3))/3.0d0
sigdiv(1,1) = sig(1,1)-pressure
sigdiv(1,2) = sig(1,2)
return
end
c
CCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCC
User-Defined Material Total Formulation Example
This sample total formulation user-defined material relating to a User-Defined Constitutive Model
(2D Only) is derived from a mat_user_total.f file:
C
SUBROUTINE MAT_USER(d,time,dtime,temp,engine_s,user_s,
1 eps,deps,sig,df)
c
c AdvantEdge 2D/3D User defined material
c Total formulation example
c
c COPYRIGHT Third Wave Systems Inc. 2013
c www.thirdwavesys.com
c
179
#ifndef linux
!DEC$ ATTRIBUTES DLLEXPORT :: MAT_USER
#endif
c
c
implicit real*8 (a-h,o-z)
c
c
c Total formulation
c
c sig(3,3) Previous and updated stress [Pa]
c sig(1,1) = Sxx, sig(2,2)=Syy, sig(1,2)=Sxy
c dtime time step [s]
c temp temperature [c]
c
c engine_s(1) Plastic strain [1]
c engine_s(3) Plastic work rate (heat generation) [w]
c engine_s(4) Plastic strain rate [1/s]
c engine_s(5) damage
c engine_s(6:15) Engine state variables
c
c user_s(1:100) User state variable
c user_s(1:5) Tecplot output with “user”
c
c deps(3,3) Deformation tensor * dtime (strain increment)
c deps(1,1) = Dxx*dtime, deps(1,2)=Dxy*dtime,
deps(2,2)=Dyy*dtime
c
c eps(3,3) Total Deformation gradient
c
c
c df(3,3) Relative Deformation gradient
c
c
c Material properties are read from _wp.twm file
c
c Reserved material parameters
c d(5) lambda (Lame’s constant)
c d(6) mu (Lame’s constant)
c d(98) Conductivity
c d(99) Specific Heat * Density
c d(100) Density
c User defined material parameters

c d(25) UMATPAR01
c d(26) UMATPAR02
c d(27) UMATPAR03
c d(28) UMATPAR04
c d(29) UMATPAR05
c d(30) UMATPAR06
180
c d(31) UMATPAR07
c d(32) UMATPAR08
c d(33) UMATPAR09
c d(34) UMATPAR10
c d(35) UMATPAR11
c d(36) UMATPAR12
c d(37) UMATPAR13
c d(38) UMATPAR14
c d(39) UMATPAR15
c d(40) UMATPAR16
c d(41) UMATPAR17
c d(42) UMATPAR18
c d(43) UMATPAR19
c d(44) UMATPAR20
c d(45) UMATPAR21
c d(46) UMATPAR22
c d(47) UMATPAR23
c d(48) UMATPAR24
c d(49) UMATPAR25
c d(50) UMATPAR26
c d(51) UMATPAR27
c d(52) UMATPAR28
c d(53) UMATPAR29
c d(54) UMATPAR30
c d(55) UMATPAR31
c d(56) UMATPAR32
c d(57) UMATPAR33
c d(58) UMATPAR34
c d(59) UMATPAR35
c d(60) UMATPAR36
c d(61) UMATPAR37
c d(62) UMATPAR38
c d(63) UMATPAR39
c d(64) UMATPAR40
c d(65) UMATPAR41
c d(66) UMATPAR42
c d(67) UMATPAR43
c d(68) UMATPAR44
c d(69) UMATPAR45
c d(70) UMATPAR46
c d(71) UMATPAR47
c d(72) UMATPAR48
c d(73) UMATPAR49
c d(74) UMATPAR50
c
c Radial Return method elastic perfect-plastic material
c
real*8 dtime,temp,d(100),engine_s(15),user_s(100),
eps(3,3), & deps(3,3),sig(3,3)
real*8 sigtr(3,3),dsig(3,3),sigdiv(3,3),df(3,3)
real*8 df_(3,3)
181
real*8 bb(3,3),temp3x3(3,3)
real*8 b_trial(3,3),s_trial(3,3)
c
c
c
c Initialize state variable
c
if ( time .le. dtime )then
engine_s(1:15)=0.0d0
eps(1:3,1:3)=0.0d0
eps(1,1)=1.0d0
eps(2,2)=1.0d0
eps(3,3)=1.0d0
user_s(1:100) = 0.0d0
end if
bb(1,1) = user_s(11) + 1.0d0

bb(2,1) = user_s(12)
bb(3,1) = user_s(13)
bb(1,2) = user_s(14)
bb(2,2) = user_s(15) + 1.0d0
bb(3,2) = user_s(16)
bb(1,3) = user_s(17)
bb(2,3) = user_s(18)
bb(3,3) = user_s(19) + 1.0d0
c Initialize plastic strain rate

engine_s(4)=0.0d0
c Initialize plastic work (heat generation)
engine_s(3)= 0.0d0
c
c Compute elastic Predictor
c
det = df(1,1)*df(2,2)*df(3,3) + df(2,1)*df(3,2)*df(1,3)
1 + df(1,2)*df(2,3)*df(3,1) - df(3,1)*df(2,2)*df(1,3)
2 - df(1,2)*df(2,1)*df(3,3) - df(3,2)*df(2,3)*df(1,1)
c
c
c
if ( det .le. 0.0d0 .or. isnan(det) ) then

c
c Failed element
c
user_s(1:15)=0.0d0
eps(1:3,1:3)=0.0d0
182
eps(1,1)=1.0d0
eps(2,2)=1.0d0
eps(3,3)=1.0d0
c
c sig(1:3,1:3) = 0.0d0
c
c p_ = dK*(det-1.0d0)
c sig(1,1)= sig(1,1) + p_
c sig(2,2)= sig(2,2) + p_
c sig(3,3)= sig(3,3) + p_
detF= eps(1,1)*eps(2,2)*eps(3,3)+eps(2,1)*eps(3,2)*eps(1,3)
1 + eps(1,2)*eps(2,3)*eps(3,1)-eps(3,1)*eps(2,2)*eps(1,3)
2 - eps(1,2)*eps(2,1)*eps(3,3)-eps(3,2)*eps(2,3)*eps(1,1)
write(6,*)”Negative det df”,det,detF
c
return
end if
c
d_c = det**(-1.0/3.0)
c
df_(1:3,1:3)= d_c*df(1:3,1:3)
forall(i=1:3,j=1:3)
temp3x3(i,j)=df_(i,1)*bb(1,j)+df_(i,2)*bb(2,j)+
1 df_(i,3)*bb(3,j)
end forall
forall(i=1:3,j=1:3)
b_trial(i,j)=temp3x3(i,1)*df_(j,1)+temp3x3(i,2)*df_(j,2)+
1 temp3x3(i,3)*df_(j,3)
end forall
c
b_trace = (b_trial(1,1)+b_trial(2,2)+b_trial(3,3))
d_i_ = b_trace/3.0d0
s_trial(1:3,1:3) = b_trial(1:3,1:3)
s_trial(1,1) = s_trial(1,1) - d_i_ !b_trace/3.0
c
183
c
s_trial(1:3,1:3)= d(6)*s_trial(1:3,1:3)
yield_str = d(25) ! Initial yield stress
s_trial_norm = umat_div_norm(s_trial)
f_trial = s_trial_norm - sqrt(3.0/2.0)*yield_str
c
c Check for plastic loading
c
if ( f_trial .le. 0.0d0 ) then

sig(1:3,1:3) = s_trial(1:3,1:3)
bb(1:3,1:3) = b_trial(1:3,1:3)
else
c
c Return-mapping algorithm
c
dmu_ = d_i_*d(6)
c
delta_gm = f_trial/(2.0d0*dmu_)
c
c Plastic Strain
engine_s(1) = engine_s(1) + delta_gm
c
c Plastic Strain rate
engine_s(4) = delta_gm/dtime
c
c Plastic work rate (heat generation)
c
engine_s(3) = delta_gm*yield_str/dtime
c
temp3x3(1:3,1:3) = s_trial(1:3,1:3)/s_trial_norm
c Return map
sig(1:3,1:3)=
1 s_trial(1:3,1:3)-2.0d0*dmu_*delta_gm*temp3x3(1:3,1:3)
c Update of intermediate configuration

bb(1:3,1:3) = sig(1:3,1:3)/d(6)
bb(1,1) = d_i_ + bb(1,1) ! -1.0d0
bb(2,2) = d_i_ + bb(2,2) ! -1.0d0
bb(3,3) = d_i_ + bb(3,3) ! -1.0d0
end if
user_s(11) = bb(1,1) - 1.0d0
184
user_s(12) = bb(2,1)
user_s(13) = bb(3,1)
user_s(14) = bb(1,2)
user_s(15) = bb(2,2) - 1.0d0
user_s(16) = bb(3,2)
user_s(17) = bb(1,3)
user_s(18) = bb(2,3)
user_s(19) = bb(3,3) - 1.0d0
c Test user_s(1:5) output

user_s(1) = engine_s(1) ! plastic strain
c
c Bulk modulus
c
! dK = d(5) + 2.0d0/3.0d0*d(6)
dK = 5.0d-1 * d(5) + d(6) / 3.0d0
c
c
c Add elastic pressure term
c
det = eps(1,1)*eps(2,2)*eps(3,3)+eps(2,1)*eps(3,2)*eps(1,3)
1 + eps(1,2)*eps(2,3)*eps(3,1)-eps(3,1)*eps(2,2)*eps(1,3)
2 - eps(1,2)*eps(2,1)*eps(3,3)-eps(3,2)*eps(2,3)*eps(1,1)
c
p_ = dK * (det - 1.0d0 / det )
sig(1,1)= sig(1,1) + p_
sig(2,2)= sig(2,2) + p_
sig(3,3)= sig(3,3) + p_
END SUBROUTINE
c
c
double precision function umat_div_norm(sigdiv)
c
c
real*8 sigdiv(3,3)
real*8 sigma_norm
c
sigma_norm = sigdiv(1,1)*sigdiv(1,1)
185
Cu st om M a t e r ia ls | Use r - D e fin e d Yie ld Su r fa ce Con st it u t ive M ode l
umat_div_norm = dsqrt(sigma_norm)
return
end
c
11.14 — User-Defined Yield Surface Constitutive Model

The user-defined yield surface (UDYS) constitutive model allows users to define a custom yield
surface by utilizing the FORTAN dynamic library. The yield surface determines when a material
model will switch from elastic to plastic and calculates stress for a given strain; therefore, only
experienced users should define these parameters. The user can define up to 100 state variables;
however, only the first five will be displayed. This will allow users to describe more advanced UDYS
constitutive models. These state variables can be updated at each time step, enabling
implementation of damage models.
The following section describes the UDYS model in detail and provides an example using the
Johnson-Cook material model.
AdvantEdge defines yield surface in terms of Von Mises stresses as
f =  s – 
1---
2
 s =  --- s ij s ij
3
where
2 
and the yield stress is assumed to be a function of the equivalent plastic strain, the strain rate and
the temperature,
 =    ·  T 
t 2 p
where  ---     d
0 3
denotes the equivalent plastic strain, · the strain rate, and T the temperature. Associated flow rule
and isotropic hardening law are assumed.
186
Linear Kinematic/Isotropic UDYS Model
AdvantEdge 2D allows the user to define a kinematic and isotropic hardening combined User-
Defined Yield Surface Constitutive Model. Isotropic hardening is when the material yield surface
changes uniformly in all directions. Kinematic hardening is used for cyclic loading with translation of
yield surface center. The decision of which model to use for a plastically deforming material
depends on which model appears to best fit the material behavior.
In AdvantEdge, the yield function is defined as
f =   –  Y   T  · 
1
---
2
where  = dev    –  = s –  and  =  ---  ij  ij .
3
2 
The backstress  defines the center of the yield surface. The evolution equation of  is given by
· 2 h   T  ·  3 h   T  ·  
 = --- -----------------------------  ----------- = -----------------------------  --------
3  2     
h   T  · 
where ----------------------------- is called the kinematic hardening modulus.

 Y   T  · 
Users must define  Y   T  ·  and -------------------------------- . They must also define theta ( 0    1 ), which is a

material parameter used to determine the combination of isotropic hardening and kinematic
hardenings.
If theta is 1, then the model acts purely like isotropic hardening. Similarly, when theta is 0, the
model becomes purely kinematic hardening. To change the value of theta, users need to add it into
the XXX_wp.twm file in a format THETA=number.
In the linear kinematic/isotropic hardening model, the following form of combined kinematic/
isotropic hardening law is used:
 Y   T  ·  =  Y + H 
where H = constant and  Y is the initial yield stress.
Solution Algorithms
Two solution algorithms are supported for User-Defined Yield Surface Constitutive Model:
187
• N e w t o n m e t h o d — requires the implementation of both the yield stress function and its
derivatives, namely  =    ·  T  , which calculates the yield stress given the equivalent
plastic strain, the strain rate and the temperature.
   ·  T 
----------------------------- , which calculates the derivative of the yield stress with respect to the equivalent

plastic strain
   ·  T 
----------------------------
- , which calculates the derivative of the yield stress with respect to the plastic strain
·
rate
• Se ca n t m e t h o d — derivatives are approximated numerically and the user only needs to

implement the yield stress function. Compared to Newton method, the Secant method may
have a lower convergence rate.
For example, in a Johnson-Cook material model the yield stress is defined as
·
   T – T room  m
   ·  T  =  A + B   1 + c ln  -----  --------------------------------
n
- 1 – -
  ·    T –T  
0 melt room
where A , B , c , n , and m are material parameters. The derivatives are
·
   ·  T  n – 1    T – T room  m
----------------------------- = Bn 1 + c ln  ----- 1 –  --------------------------------
-
   a·    T – T  
0 melt room
   ·  T  n  c  T – T room  m
 --------------------------------
----------------------------
- =  A + B  --- 1 – -
·  ·   T –T  
melt room
Implementation
User-Defined Yield Surface Constitutive Model (and its derivatives) should be implemented in
FORTRAN and compiled by Intel FORTRAN compiler. The name of the dll should be
UserYieldSurface.dll and AdvantEdge should load this dll at run time.
A sample code, which implements the Johnson-Cook yield stress and its derivatives, is provided in
mat_user_yield_surface.f with the release package. All previously-run UDYS subroutines must be
updated to run in AdvantEdge version 5.8 or newer. The definition of subroutines to calculate the
yield stress and its derivative yield are given below:
SUBROUTINE mat_user_yield_surface(d, yield, eps, eps_rate, temp,
& dt, user_s, nvar, kStep)
c
c Sample code for user defined yield surface, Jan. 2009
188
c
c d(1:50) UMATPAR01-UMATPAR50 Material parameters
c yield Yield stress [Pa]
c temp Temperature [c]
c eps Equivalent plastic strain [1]
c eps_rate Equivalent plastic strain rate [1/s]
c dt Incremental time step [s]
c user_s(1:nvar) User state variables
c kStep Time step count
implicit none
double precision d(*), yield, eps, eps_rate, temp, dt, user_s(*)
integer nvar, kStep
SUBROUTINE mat_user_yield_surface_deriv(d, dyield, eps, eps_rate,
& temp, dt, user_s, nvar, kStep)
c
c
c dyield Yield stress [Pa]
implicit none
double precision d(*), dyield, eps, eps_rate, temp, dt, user_s(*)
integer nvar, kStep
A third subroutine updates the state variables at each time step. This subroutine will enable usage
of Damage models along with UDYS. The definition of this subroutine is given below:
SUBROUTINE mat_user_yield_surface_update_state(d, eps, eps_rate,
& temp, dt, user_s, nvar, sigma, kStep)
c
c
c yield Yield stress [Pa]
c sigma(1:6) Stress tensor
c sigma(1) Sxx
189
c sigma(2) Syy
c sigma(3) Szz
c sigma(4) Sxy
c sigma(5) Syz
c sigma(6) Szx
implicit none
double precision d(*), yield, eps, eps_rate, temp, dt, user_s(*),
& sigma(*)
The input arguments are:
• d ( 1 : 5 0 ) stores the user-defined material parameters;
• e p s is the equivalent plastic strain, 
• e p s_ r a t e is the plastic strain rate, ·
• t e m p is the temperature, T
• d t is the incremental time step, needed for derivative computation

• u se r _ s is the state variable
• n v a r is the number of state variables
• k St e p is the time step count
Material Parameters
The following material parameters are reserved and shared by the AdvantEdge engine; they must
be defined with the corresponding keywords when applying User-Defined Yield Surface Constitutive
Model:
Ta ble 1 1 .1 : M a t e r ia l Pr ope r t y Ke yw or d D e fin it ion s
M a t e r ia l Pr ope r t y Ke yw or d
Young’s Modulus YOUNG
Poisson’s Ratio POISSON
Thermal Conductivity CONDUCTIVITY
Heat Capacity HEATCAP
Density DENSITY
Thermal Expansion Coefficient ALPHA
50 material parameters are allowed in the user-defined yield stress (and derivative) subroutine.
They are defined with keyword from UMATPAR01 to UMATPAR50. These parameters will be passed to the
user subroutine through the d(1:50) array. Users should maintain the consistency between the
definitions of these parameters and their references in the user-defined subroutines.
190
Yield Surface Constitutive Model Setup
Below is a list of steps to follow when setting up a User-Defined Yield Surface Constitutive Model
simulation that uses a yield surface constitutive model:
1. Create a 2D or 3D simulation
2. Click the Cu st o m radio button within the Workpiece Material window
3. Select Cu st o m M a t e r i a l s > Co n st i t u t i v e M o d e l > U se r D e f i n e d Y i e l d Su r f a ce
4. Select W o r k p i e ce M a t e r i a l > W o r k p i e ce M a t e r i a l > M a t e r i a l “ X ”.
5. Define thermal properties, elastic properties, and user-defied yield surface parameters
within the Custom Material window.
Fi g u r e 1 1 - 1 9 : H e a t T r a n sf e r t a b o f Cu st o m M a t e r i a l w i n d o w
Fi g u r e 1 1 - 2 0 : El a st i c t a b o f Cu st o m M a t e r i a l w i n d o w
191
Fi g u r e 1 1 - 2 1 : U se r D e f i n e d P a r a m e t e r t a b o f Cu st o m M a t e r i a l w i n d o w w i t h U se r D e f i n e d
P a r a m e t e r w i n d o w sh o w i n g m a t e r i a l p r o p e r t i e s f o r Jo h n so n - Co o k M o d e l e x a m p l e
6. Within the State Variable tab of the Custom Material window, input the number of state
variables to be used, from 5 to 100
Fi g u r e 1 1 - 2 2 : St a t e V a r i a b l e t a b o f Cu st o m M a t e r i a l w i n d o w
7. Sa v e the project
8. Change/Verify keyword within the *_wp.twm file. The DERIV= keyword parameter will be
present within the *_wp.twm file, and specifies the solution algorithm desired. D ER I V = 1 . 0
i s f o r t h e N e w t o n M e t h o d , which requires the user to implement the yield stress and
its derivatives; DERIV=0.0 represents the Secant Method, which requires the user to imple-
ment the yield stress. If the keyword DERIV does not exist within the file, it will be treated
as DERIV=1.0.
192
9.I If the user is utilizing the sample Johnson-Cook model, this step can be skipped. Other-
wise follow the steps below:
 Implement the user-defined yield stress or the yield stress and its derivatives
 Compile the user-defined yield stress subroutine to a dll by typing the following com-
mand in the Intel Fortran compiler command prompt:
>ifort /DLL /libs:static /threads mat_user_yield surface.f
 Rename the dll to UserYieldSurface.dll
 Replace any existing UserYieldSurface.dll within the advanteng bin with the new Use-
rYieldSurface.dll
10. Submit the simulation
User-Defined Yield Surface Temperature Dependent Table
The user-defined yield surface temperature dependent table is an extension of User-Defined Yield
Surface Constitutive Model that allows the user to define heat conductivity and heat capacity as a
function of temperature. This feature is useful when modeling materials that are sensitive to heat
capacity at certain temperatures. Below are the necessary steps for defining the temperature
dependent thermal conductivity and heat capacity:
1. Create a 2D or 3D simulation
2. Activate the Cu st o m radio button within the Workpiece Material window
3. Select Cu st o m M a t e r i a l s > Co n st i t u t i v e M o d e l > U se r D e f i n e d Y i e l d Su r f a ce
4. Select W o r k p i e ce M a t e r i a l > W o r k p i e ce M a t e r i a l > M a t e r i a l “ X ”. The Custom
Material window will open.
5. Within the Conductivity tab of the Custom Material Window, click the T e m p e r a t u r e
D e p e n d e n t T a b l e button
6. Within the Temperature Dependent Table window, add a new row by clicking A p p e n d
7. Input the temperature value (°C) and press En t e r ; then input the thermal conductivity
value (W/m °C) and press En t e r . Repeat as necessary and, when finished, click O K.
193
Fi g u r e 1 1 - 2 3 : Co n d u ct i v i t y t a b o f Cu st o m M a t e r i a l w i n d o w w i t h T e m p e r a t u r e D e p e n d e n t
T a b l e o p e n t o sh o w T h e r m a l Co n d u ct i v i t y t a b
8. Within the Heat Capacity tab of the Custom Material Window, click the T e m p e r a t u r e
D e p e n d e n t T a b l e button
9. Within the Temperature Dependent Table window, add a new row by clicking A p p e n d
10. Input the temperature value (°C) and click En t e r ; then input the corresponding heat
capacity value (J/kg °C) and click En t e r. Repeat as necessary and, when finished, click
O K.
Fi g u r e 1 1 - 2 4 : H e a t Ca p a ci t y t a b o f Cu st o m M a t e r i a l w i n d o w w i t h T e m p e r a t u r e D e p e n d e n t
T a b l e o p e n t o sh o w H e a t Ca p a ci t y t a b
11.Within the State Variable tab of the Custom Material window, input the number of state
variables to be calculated at each material point
194
Cu st om M a t e r ia ls | I m por t in g a n d Ex por t in g M a t e r ia l File s
N ot e : Regardless of the number of variables designated, Tecplot will only display the first
five state variables.
11.15 — Importing and Exporting Material Files

Custom Materials can be exported and imported so that once a material is created, it does not need
to be created again. The files are exported in Metric units; however, when importing into an English
unit setup, no action on the user’s part will be necessary. This import/export feature is available for
all custom material options within the Custom Material window. To open the Custom Material
window, select Cu st o m M a t e r i a l s > W o r k p i e ce M a t e r i a l > M a t e r i a l 1 . The import and
export buttons are located at the bottom of the Custom Material window.
Fi g u r e 1 1 - 2 5 : Cu st o m M a t e r i a l w i n d o w
When importing files, files must have *.twm extensions, but do not need to be in the same directory
as the project file
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CHAPTER 12 — 2D SIMULATION
OPTIONS
Simulation options can be defined in AdvantEdge once 2D Tool Setup, 2D Workpiece Setup, and 2D
Process Setup have been established. Depending on information defined by the user, the simulation
setup may significantly affect the simulation time and accuracy, and type of results generated by
AdvantEdge. To open the Simulation Options window, select Si m u l a t i o n > Si m u l a t i o n
O p t i o n s. Within the Simulation Options window are four tabs relating to General Options, Meshing
Options, Results Options, and Parallel Processing.
12.1 — General Options

Under the General tab of the 2D Simulation Options window, the user defines the Simulation Mode,
whether Residual Stress Analysis is desired, the type of post-cut analysis to be done, and
Simulation Constraint.
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2 D Sim u la t ion Opt ion s | Ge n e r a l Opt ion s
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Simulation Mode
Simulations can run in demonstration or standard mode, and may be set within the General Options
tab of the Simulation Options window. The default setting and recommendation is standard mode.
• D e m o n st r a t i o n m o d e will decrease simulation time; however, it will provide less accurate

results. The mesh and algorithms produced by demonstration mode may significantly affect
simulation accuracy. Due to the decrease in accuracy, demonstration mode should only be
conducted to gain visual information about the setup. It should not be used for force
validation or complex analyses.
• St a n d a r d m o d e requires longer simulation time, but provides more accurate results. It
also allows advanced options such as Residual Stress Analysis to be utilized. Standard
simulations are more reliable, accurate, and robust than demonstration simulations.
Chip Breakage
The chip breakage option within the General Options tab of the Simulation Options window will
predict whether or not chips will break, and display the chip shapes. This option will inherently take
more simulation time due to extra calculations. The length of cut should also be set to be longer, so
the generated chips are long enough to break.
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Residual Stress Analysis
The residual stress analysis option within the General Options tab of the Simulation Options window
requires a standard Simulation Mode, and will also drastically increase computation time due to the
low coarsening of the mesh and the additional thermo-mechanical calculations. Users must specify
the number of cuts (1 or 2) using the dropdown list; AdvantEdge defaults to 1 cut.
Residual stress analysis requires more calculation than standard cutting, as the finished part of the
workpiece does not coarsen its mesh. Users can change depth of mesh refinement by entering a
value into the Depth of Mesh Refinement for Residual Stress Analysis area located in the General
tab of the Simulation Options Window (for more, see Depth of Mesh Refinement for Residual Stress
Analysis). Cut elements within this depth of the workpiece will not be coarsened during residual
stress analysis. After the cut is finished, both the chip and tool are removed and the workpiece is
allowed to thermo-mechanically relax. The heat is dissipated and the mechanical vibrations die out.
A state of stress in the workpiece is then shown.
A two-cut residual stress simulation will take more than twice as long as a one-cut simulation. In
general, expect residual stress simulations to take a very long time.
R e si d u a l st r e ss a n a l y si s i s n o t a l l o w e d f o r 2 D M i l l i n g . It is suggested that the user set

up a turning simulation and input feed as a maximum chip load case.
N ot e : Residual stress analysis and Steady State Analysis cannot be performed in the
same simulation.
Steady State Analysis
Steady state analysis allows the user to compute steady state forces and stresses over a desired
length of cut. Cutting conditions just before the end of the prescribed cut are used to perform the
steady state heat transfer analysis based on heat generation. This provides further insight into the
tool condition after the prescribed length of cut. Generally this feature adds 30 minutes to the
computation time.
To enable steady state analysis, check the St e a d y St a t e A n a l y si s checkbox within the General
Options tab of the Simulation Options window. By default, the average length of cut is set to 10%;
this means the averaged cutting conditions over the last 10% of the cut will be used to determine
the loading conditions.
Steady state analysis is only possible for turning, sawing, and broaching processes.
N ot e : Residual Stress Analysis and steady state analysis cannot be performed in the same
simulation.
N ot e : When using a custom tool (see Custom and Imported Tools), the top and right sides
of the tool must have prescribed thermal boundary conditions. If the user does not
prescribe the thermal boundary conditions, the tool will be assumed to be adiabatic
and will not reach a steady-state solution. For a standard tool, these sides have a
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2 D Sim u la t ion Opt ion s | M e sh in g Opt ion s
default thermal boundary condition set at 20ºC. For more, see Set Boundary
Conditions.
Simulation Constraint
The simulation constraint option within the General Options tab of the Simulation Options window
provides an automated analysis warning and simulation termination capability when either peak
cutting tool normal stress values and/or temperature values exceed a user-defined constraint. This
will allow users to save CPU time when simulating a number of cases where peak tool temperature
and/or peak tool normal stress is the main output variable of interest. This option is available for 2D
analyses only.
The values for normal stress and/or temperature constraints must be entered by the user. If during
the simulation, the peak tool temperature or normal stress averaged over the specified number of
steps exceeds these constraint values, the analysis will be terminated, and the message
“Termination” will be displayed in the status section of the AdvantEdge Job Monitor. A Tecplot zone
will be written prior to the analysis termination.
Maximum Number of Nodes
The Maximum Number of Nodes option within the General Options tab of the Simulation Options
window allows the users to adjust the maximum number of nodes the simulation can use.
AdvantEdge defaults to 12000 nodes. Some very detailed analysis requires more nodes and
subsequently more elements.
N ot e : The more nodes input, the more RAM needed. Some computers may not be able to
handle large increases in nodes.
12.2 — Meshing Options

Within the Meshing tab of the 2D Simulation Options window, users may choose to change meshing
values; however, since even slight changes can significantly alter simulation performance and
accuracy, this option should only be utilized by advanced AdvantEdge users.
It is always good practice to first run a simulation with the default meshing parameters. A
simulation that appears to need more refined meshing parameters may actually run sufficiently
with the default meshing parameters. Running this practice check could save users valuable
computational time.
The default values have been chosen for their balance of computation time and accuracy. It is worth
noting that these default values may not always be suitable for every simulation (especially those
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with geometries that differ significantly from default inputs). Default values are different for Micro-
Machining simulations and for these case, it should be understood they are only guidelines.
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Minimum/Maximum Element Size
Within the Meshing Options tab of the Simulation Options window, Minimum/maximum element
size refers to the smallest/largest edge length for a coarsened (refined) element. Decreasing the
element size increases the computation time quadratically. Generally, the user will need to decrease
these parameters if the workpiece geometry (see 2D Workpiece Setup) or tool geometry (see 2D
Tool Setup) is significantly smaller than default values. The simulation at right below
(Max = 0.05 mm, Min = 0.01 mm) generated more accurate results; however, it took
approximately four times as long to run compared to the simulation at left below (Max = 0.1 mm,
Min = 0.02 mm).
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N ot e : AdvantEdge takes the smallest calculated minimum element size of minimum

element size, fraction of Cutting Edge Radius to determine minimum element size,
and Feed Fraction to determine minimum element size, as the minimum element
size. For example, if a user specifies a minimum element size of 0.1 mm and a feed
fraction of 0.1, the element size calculated by the fraction of feed will be 0.01 mm.
Therefore, AdvantEdge will use 0.01 mm as the minimum element size in the
simulation.
N ot e : The minimum element size used in simulation is determined from the lowest of
three user inputs: minimum element size, Cutting Edge Radius fraction, and Feed
Fraction. From each of these values an element size is calculated, the smallest of
which is used in simulation as the minimum element size (see Determining
Minimum Element Size).
Determining Minimum Element Size
CUTTI N G ED GE RAD I US
Within the Meshing Options tab of the Simulation Options window, the cutting edge radius to
determine minimum element size defines the element length in the vicinity of the cutting edge. This
will be the ratio of the minimum element size to the edge radius of the tool.
The AdvantEdge default value of 0.6 mm should be sufficient for most simulations. However, in the
case of especially large or small cutting edge radii, this may need to be altered. The simulation at
left below contained twice the fraction of cutting edge radius as the simulation at right. However,
the simulation at right below had a more refined mesh near the vicinity of the tool edge.
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element size, fraction of cutting edge radius to determine minimum element size,
and Feed Fraction to determine minimum element size, as the minimum element
simulation.
FEED FRACTI ON
Within the Meshing Options tab of the Simulation Options window, the feed fraction to determine
minimum element size option defines the smallest element length through the chip thickness as a
fraction of feed. Thus, this parameter determines the number of elements that will be present
through the thickness of the feed. The default setting in AdvantEdge is 0.1 mm, which means that
there will be 10 elements for the input feed. The simulation at left below has twice the feed
fraction; however, the simulation at right below has a finer mesh, especially near the tool edge.

element size, fraction of Cutting Edge Radius to determine minimum element size,
and feed fraction to determine minimum element size, as the minimum element
simulation.
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Mesh Refinement Factor
Within the Meshing Options tab of the Simulation Options window, the mesh refinement factor
determines the aggressiveness of mesh refinement during deformation, such as how fast the mesh
is refined to its smallest size. Making the mesh refinement factor finer will increase the number of
nodes in the simulation and thus, increase computational time. The simulation at left below used
the default mesh refinement factor; the simulation at right below had a refinement factor of 5,
displaying a finer mesh near the tool and around areas of high strain due to the more aggressive
refining.
Mesh Coarsening Factor
Within the Meshing Options tab of the Simulation Options window, the mesh coarsening factor
determines the aggressiveness of element coarsening for elements with little deformation, such as
how fast the mesh is coarsened to its largest size. Making the mesh coarsening factor finer will
increase the number of nodes in a simulation because the mesh will stay refined in areas of low
deformation. The simulation at left below used the default mesh coarsening factors; the simulation
at right below had a mesh coarsening factor of 6 and thus, was less aggressively coarsened. The
simulation at right below displayed a finer mesh throughout the whole chip – indicative of the fact
that it was less aggressively coarsened.
In general, the suggested minimum element size, cutting edge radius to determine minimum
element size, and feed fraction inputs are checks on each other to minimize need for the user to
change parameters. For example, if a user has defined a very small feed, AdvantEdge will
recognize\the need for a finer mesh and make the minimum element size the entered fraction of
the feed.
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2 D Sim u la t ion Opt ion s | Re su lt s Opt ion s
Depth of Mesh Refinement for Residual Stress Analysis
Within the Meshing Options tab of the Simulation Options window, the depth of mesh refinement for
residual stress analysis option applies to the cut part of the workpiece, within which elements will
not be coarsened during Residual Stress Analysis. This feature ensures that the residual stress
analysis will be accurate, and will not be available unless a residual stress analysis has been
selected within the General Options tab of the Simulation Options window.
12.3 — Results Options

The Results tab of the 2D Simulation Options window allows users to define how results will be
viewed in the contour plot, as well as request specific history outputs and cutting force information.
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Number of Output Frames
The N u m b e r o f O u t p u t Fr a m e s input box within the Results Options tab of the Simulation
Options window allows users to specify the number of frames AdvantEdge will write for viewing in
Tecplot. By default, the number of frames is 30. A higher number of frames will result in a smoother
animation; however, it will also increase computation time and file size.
N ot e : Although there is no limit to the number of frames a user can enter, it is suggested
to request no more than 200 frames, as anything more could result in an Out of
Virtual Memory error. It is usually a good practice to proportion the number of
frames with the simulation length of cut. For example, if a user runs a simulation
with a length of cut of twice the default parameter for that given simulation, the
amount of output frames could be doubled from the default 30 frames, to
60 frames. However, if visual display is of no importance to the user, the number of
frames can remain set at 30, as this will not decrease the accuracy of computation.
For visual result purposes, it is recommended to increase the number of frames by 25%. Taking the
example presented above, the user could run the simulation with 75 frames and achieve a
smoother animation.
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Define Output Window
By checking the D e f i n e O u t p u t W i n d o w checkbox within the Results Options tab of the

Simulation Options window, users can request additional frames for up to 10 specific regions of the
simulation. These focus areas, considered “windows” of the simulation, can be defined specifying a
starting and ending length of cut, between which the additional frames (to be indicated in the
Number of Output Frames area of the window definition) will be collected.
This feature smooths the animation during the specified regions (“windows”) without considerably
increasing the overall size of output files and computation time.
Additional Outputs
AdvantEdge can output various histories, including Contact Traction, Tool Deflection, Tool Stress,
and Cutting Forces for Each Flute. These outputs - which are selected within the Results Options tab
of the Simulation Options window - will become available in Tecplot once results have been
calculated. For stress history, it is recommended to average over the highest 10% of the elements.
N ot e : By default, all additional outputs are disengaged within AdvantEdge. To obtain

these specific outputs, the user must activate the options before running the
simulation.
CON TACT TRACTI ON
When the contact traction feature is activated, AdvantEdge will compute the average contact
traction (normal and tangential) at the tool-workpiece interfaces. Contact tractions are averaged
over the active contact surfaces. Active contact surfaces are those surfaces that are actually in
contact at a specific instant in time. Once the simulation is complete, the user can view these
computations on a time history plot. These calculations will appear as Contact Shear and Contact
Pressure on the time history plot (for more, see Time History Tab within the AdvantEdge Quick
Analysis section). To obtain this data, the user must check the O u t p u t Co n t a ct T r a ct i o n T i m e
H i st o r y checkbox before running the simulation.
TOOL D EFLECTI ON
The top surface of a tool has prescribed rigid body rotations applied as boundary conditions for
milling and drilling simulations. When this option is selected, AdvantEdge will calculate deflection X,
deflection Y, and deflection Z. The user can activate this option by checking the O u t p u t T o o l
D e f l e ct i o n T i m e H i st o r y checkbox within the Simulation Options window. After a simulation has
completed, the user can view the tool deflections on a time history plot (for more, see Time History
Tab within the AdvantEdge Quick Analysis section).
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2 D Sim u la t ion Opt ion s | Pa r a lle l Pr oce ssin g
TOOL STRESS
If the user activates the tool stress option, AdvantEdge will compute the averaged Mises stresses in
a tool. After the simulation has completed, the user can view the averaged Mises stress on a time
history plot (for more, see Time History Tab within the AdvantEdge Quick Analysis section). To
activate this feature, check the O u t p u t T o o l St r e sse s T i m e H i st o r y checkbox within the
Simulation Options window. By default, the stress history is average over the highest 10% of the
elements.
CUTTI N G FORCES FOR EACH FLUTE
For milling and drilling process, the user can decide to calculate the cutting forces for every flute.
This feature can be activated by checking the O u t p u t Cu t t i n g Fo r ce s f o r Ea ch Fl u t e
checkbox. The user can view the calculated forces within Tecplot once the simulation has completed
(for more, see Results Analysis: Tecplot).
12.4 — Parallel Processing

Reductions in wall-clock or elapsed time are achieved via parallel computation by spawning multiple
threads on multi-core machines. In the computing framework, one thread uses one core. A thread
has a software process connotation, while a core has a computer hardware connotation. Generally,
elapsed times will continue to reduce with the increase in threads used, up to the number of
available cores on the computing hardware. Most contemporary hardware configurations are
suitable for parallel computing. Computers using CPUs with multiple cores and/or multiple
processors are able to utilize parallel computing.
To speed up AdvantEdge simulations with multiple duo/quad core processors, parallel processing
capabilities are available. This feature can be activated using the Parallel tab of the 2D Simulation
Options window.
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N UM BER OF PARALLEL CORES
The text input box for specifying the number of parallel cores in the Parallel tab can be used to set
the number of cores for a specific simulation. The user may input an integer number from 1 – 60
cores, but will need this number of parallel or flexible license cores available to run this simulation.
The license monitor can be used to determine how many cores are currently available and the types
of licenses the user has access to. The license monitor can be opened by clicking the License
Monitor button below the number of parallel cores.
N ot e : This feature will only allow parallel processing based on the license the user has
access to. For more information on upgrading your current license to increase your
parallel processing capability, please contact Third Wave Systems at
sales@thirdwavesys.com.
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LI CEN SE M ON I TOR
From Simulation Options the user can open the License Monitor by selecting the License Monitor
button shown in figure 12-4. This will open the Third Wave License Monitor window. Please see
License Monitor for more details.
210
CHAPTER 13 — 3D SIMULATION
OPTIONS
Simulation options can be defined in AdvantEdge once the 3D Tool Setup, 3D Workpiece Setup, and
3D Process Setup have been established. Depending on information defined by the user, the
simulation setup may significantly affect the simulation time and accuracy, and type of results
generated by AdvantEdge. To open the Simulation Options window, select Si m u l a t i o n >
Si m u l a t i o n O p t i o n s. Within the Simulation Options window are four tabs relating to General
Options, Meshing Options, Results Options, and Parallel Processing.
13.1 — General Options

Under the General tab of the 3D Simulation Options window, the user defines the Simulation Mode,
selects Residual Stress Analysis, specifies Steady State Analysis, and defines cutter body modeling
type.
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Simulation Mode
Simulations can run in demonstration or standard mode, which is set within the General Options tab
of the Simulation Options window. The default setting and recommendation is standard mode.
• D e m o n st r a t i o n m o d e will decrease simulation time; however, it will provide less accurate

results. The mesh and algorithms produced by demonstration mode may cause significant
affects on any simulation’s accuracy. Due to the decrease in accuracy, demonstration mode
should only be conducted to gain visual information about the setup. It should not be used
for force validation or complex analyses.
• St a n d a r d m o d e requires longer simulation time, but provides more accurate results. It
also allows advanced options such as Residual Stress Analysis to be utilized. Standard
simulations are more reliable, accurate, and robust than demonstration simulations.
Residual Stress Analysis
The residual stress analysis option within the General Options tab of the Simulation Options window
requires a standard mode simulation, and will also drastically increase computation time due to the
low coarsening of the mesh and the additional thermo-mechanical calculations. Users must specify
the number of cuts (1 or 2) using the dropdown list; AdvantEdge defaults to 1 cut.
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Within the Meshing Options tab of the Simulation Options window, the values in the Minimum/
Maximum Element Size section for minimum element edge length chip bulk and cutter edge are
recommend to be identical so that the mesh retains its refinement after the tool has passed over
the workpiece. This enables the calculations made during relaxation to be more accurate. The
suggested rule of thumb is to have the minimum element edge length value be one-third of the
feed value.
The depth of mesh refinement can also be adjusted in the Meshing Options tab. Generally, this
number should be between 0.4 mm and 0.6 mm.
N ot e : Residual stress analysis and Steady State Analysis cannot be performed in the
same simulation.
Steady State Analysis
Steady state analysis allows the user to compute steady state forces and stresses over a desired
length of cut. Cutting conditions just before the end of the prescribed cut are used to perform the
steady state heat transfer analysis based on heat generation. This provides further insight into the
tool condition after the prescribed length of cut. Generally this feature adds 30 minutes to the
computation time.
To enable steady state analysis, check the St e a d y St a t e A n a l y si s checkbox within the General
Options tab of the Simulation Options window. The average length of cut is set to 10% by default.
This means the averaged cutting conditions over the last 10% of the cut will be used to determine
the loading conditions.
Steady state analysis is not possible for every process. AdvantEdge 3D permits steady state
analysis for turning, drilling, grooving, tapping, and boring processes.
N ot e : Residual Stress Analysis and steady state analysis cannot be performed in the same
simulation.
N ot e : When using a custom tool, the top and right sides of the tool must have prescribed
thermal boundary conditions. If the user does not prescribe the thermal boundary
conditions, the tool will be assumed to be adiabatic and will not reach a steady-
state solution. For a standard tool, these sides have a default thermal boundary
condition set at 20°C.
13.2 — Meshing Options

Users have the option to alter the workpiece meshing parameters; however, these modifications
may affect performance and accuracy. Therefore, workpiece meshing options should only be utilized
by advanced AdvantEdge users. Meshing parameters selected within the Workpiece Meshing tab of
the 3D Simulation Options window are important for successful 3D simulations.
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Minimum element edge length and the radius of regined region values are calculated differently
depending on the process. Turning, boring, grooving, tapping and solid drilling are all calculated
based on the feed input in the process parameters. In milling, these values are calculated using
maximum chip load based on the feed per tooth and the radial depth of cut. For all of these
processes, these meshing values will be recalculated every time the process parameters for these
simulations are changed. If you choose to change these meshing values, it is best to change them
last after changing the process parameters. Indexable drilling uses a method different from each of
the other processes. Due to the complex nature of the chip load in indexable drilling, the mesh
parameters are defined AFTER initial meshing by default. These values are based on both the
maximum chip load detected and the average chip load along the cutting edge of the tool.
Advanced users can disable this automatic calculation by unchecking the Automatic Detection box.
If automatic detection is off, the meshing parameters will be required to be changed manually and
will not change based on the feed or other process parameters.
• M i n i m u m El e m e n t Ed g e Le n g t h ( Ch i p Bu l k ) — defines the minimum edge length of

elements surrounding the refined region. By default, this value is 17/13 times the minimum
element edge length (cutter edge).
• M i n i m u m El e m e n t Ed g e Le n g t h ( Cu t t e r Ed g e ) — defines the minimum edge length
of elements near the cutting edge, which is within the refined region
• R a d i u s o f R e f i n e d R e g i o n — determines the size of the refined region, which is near the
cutting edge. The refined region is a cylindrical volume with its center lying along the
theoretically sharp edge of the tool. To determine this volume, the back rake angles are
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automatically taken into account. By default, the radius of refined region is 1.5 times the
feed. When the radius increases, the computation time also increases.
• M e sh R e f i n e m e n t Fa ct o r — determines the aggressiveness of mesh refinement during
deformation (how quickly the mesh is refined to its smallest size). By default, the mesh
refinement factor is 1. The user can refine the mesh by selecting a larger number from the
dropdown menu. 2D Simulation Options work in a similar manner.
• M e sh Co a r se n i n g Fa ct o r — determines the aggressiveness of element coarsening after
deformation (how quickly the mesh is coarsened to its largest size). AdvantEdge initially sets
the mesh coarsening factor to 5. Selecting values closer to 1 slows the rate at which the
mesh coarsens.
• Ch i p R e f i n e m e n t Fa ct o r — By default, AdvantEdge sets the chip refinement factor to 1,
which is equivalent to previous versions. When this factor is changed to 3, mesh coarsening
of the chip is disabled. The table below shows the chip refinement factor compared to the
chip element size.
Ta ble 1 3 .1 : Ch ip Re fin e m e n t Fa ct or
Ch ip Re fin e m e n t Fa ct or Ch ip Ele m e n t Size
1 Coarse
2 Medium
3 Refined
• Gr a d i n g N e a r Cu t t i n g Ed g e — defines the tolerance for the workpiece mesh gradation

within the gradation region. If mesh gradation (defined below) is greater than given
Tolerances, the engine will refine the workpiece mesh. By default, this parameter is set to 6.
 M e sh Gr a d a t i o n is equivalent to the longest edge length divided by the shortest edge
length, where each edge is in contact with a specific node. Mesh gradation controls how
quickly the workpiece mesh transitions from the minimum element edge length (cutter
edge) to the minimum element edge length (chip bulk).
• Gr a d i n g R a d i u s Fa ct o r — allows users to control the region over which the mesh
gradation is applied. The grading radius factor is a dimensionless scaling factor that,
multiplied by 2 times the radius of refined region, determines the size of the gradation
region. By default, this parameter is set to 1.
Exam ple:
Radius of Refined Region = 0.225 mm

Grading Near Cutting Edge= 4
Grading Radius Factor = 2
Gradation Region Radius = 2*Radius of Refined Region
*Grading Radius Factor
= 2*0.225 mm*2
= 0.9 mm
When the mesh gradation of any node within 0.9 mm of the cutting edge is larger than 4, the
engine will adaptively re-mesh. The gradation region and refined region for this example are shown
below:
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AUTOM ATI C CH I PLOAD D ETECTI ON FOR I N D EXABLE D RI LLI N G
AdvantEdge determines both maximum and average chip loads for indexable drilling. The maximum
and average chip loads are found for all cutting inserts, including areas with cutting overlap.
These values are then used to accurately suggest adaptive remeshing parameters based on the
actual chip cross-section being formed. The results AdvantEdge finds are externally verified to
ensure accuracy.
13.3 — Results Options

The Results tab of the 3D Simulation Options window allows users to define how results will be
viewed in the contour plot, as well as request specific history outputs and cutting force information.
Features in this tab are consistent between 2D and 3D simulations, with the additional option of
tool deflection time history and cutting forces/flute outputs for 3D simulations. For full descriptions
of result parameters, see Results Options.
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13.4 — Parallel Processing

Reductions in wall-clock or elapsed time are achieved via parallel computation by spawning multiple
threads on multi-core machines. In the computing framework, one thread uses one core. A thread
has a software process connotation, while a core has a computer hardware connotation. Generally,
elapsed times will continue to reduce with the increase in threads used, up to the number of
available cores on the computing hardware. Most contemporary hardware configurations are
suitable for parallel computing. Computers using CPUs with multiple cores and/or multiple
processors are able to utilize parallel computing.
This feature can be activated using the Parallel tab of the 3D Simulation Options window. The text
input box for specifying the number of parallel cores can be used to set the number of cores for a
specific simulation. The user may input an integer number from 1 – 60 cores, but will need this
number of parallel or flexible license cores available to run this simulation. The license monitor can
be used to determine how many cores are currently available and the types of licenses the user has
access to.
N ot e : This feature will only allow parallel processing based on the license the user has
access to. For more information on upgrading your current license to increase your
parallel processing capability, please contact Third Wave Systems at
sales@thirdwavesys.com.
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For 3D simulations, the following line will be added to the batch file: advanteng3d.exe –P[Number of
Cores] < [.inp file] > [.out file]
The overall reduction in elapsed time of the computation will be hardware and problem dependent.
Generally, larger computations (i.e., larger numbers of workpiece elements) will scale better. This
does not necessarily translate to computations with longer simulation times. For instance, a
computation with relatively few elements and a coarse mesh running for a very long length of cut
would not scale as well as a computation with large number of workpiece elements.
For more on 3D parallel processing, see 3D Parallel Processing Considerations.
If the user has the parallel processing capability, they may wish to use the License Monitor to
determine how many licenses are still available before selecting the number of cores to utilize.
LI CEN SE M ON I TOR
From Simulation Options the user can open the License Monitor by selecting the Lice n se M on it or
button shown in figure 13-5. This will open the Third Wave License Monitor window. Please see
License Monitor for more details.
218
CHAPTER 14 — 2D PARAMETRIC
STUDY
Creating multiple simulations is easier with the AdvantEdge Parametric Study Interface window.
Using this feature, user can set up a set of simulations by varying up to four cutting conditions by a
factor of 3 (i.e. 3 values each for cutting parameters feed, cutting speed, rake angle, edge radius,
and custom tools). This feature is only available in AdvantEdge 2D.
Fi g u r e 1 4 - 1 : P a r a m e t r i c St u d y I n t e r f a ce w i n d o w
To utilize the Parametric Study feature, follow the instructions below:
1. Set up a basic simulation, including parameters that will not change (tool and workpiece
materials, depth of cut, workpiece geometry) - see 2D Tool Setup
2. Save the simulation (see Saving Simulation Files)
3. Open the Parametric Study Interface window by selecting D e si g n > P a r a m e t r i c
St u d y I n t e r f a ce
219
2 D Pa r a m e t r ic St u dy |
4. Click on the desired radio buttons and select the corresponding number of levels for each
parameter
5. Input the values and click O K. All the input files for the study will be created in the same
directory where the root simulation was saved, with the following nomenclature:
job_[speed]_[feed]_[rake_angle].* The created *.twd parameter file may be used to apply
the same parameters to another project file at a later date.
N ot e : For Milling simulations, the cutting speed parameter [V] will be replaced with a
spindle speed parameter [rpm]. The user can then utilize the created files in a
batch job (for more, see Submitting a Batch Job). This will increase productivity
and AdvantEdge ease of use.
220
CHAPTER 15 — SIMULATION
MANAGEMENT
Simulations defined in AdvantEdge can be managed by first Saving Simulation Files, which
automatically creates the necessary input files.
N ot e : Before opening projects set up in previous versions of AdvantEdge, first save them
in the newest version to
15.1 — Saving Simulation Files

To save simulation files, select P r o j e ct > Sa v e . Users will be prompted to browse for the folder in
which the simulation should be saved.
When simulations are saved in AdvantEdge, several files are actually created for future use: a *.twp
file, a *.twt file, a *.inp file, and multiple *.twm files. These files will include the project name as
part of, or as the entire, file name; *.twm material files will automatically have the format
[project_name]_[component using material].twm. When transferring simulation setups, all of these
created files will be needed.
Saving Batch Files
To create a batch file, select Si m u l a t i o n > Ba t ch Jo b > Cr e a t e / Ed i t Ba t ch Fi l e . Users will

be prompted to name the file (*.bat extension) and specify a path to which the batch file will be
saved. To select the jobs to include in the batch, click the A d d button and browse for each
simulation.
221
Sim u la t ion M a n a ge m e n t | Job M on it or
N ot e : The order in which jobs are selected is the order in which they will run.
Simulation Input/Output Files
Ta ble 1 5 .1 : Sim u la t ion I n pu t / Ou t pu t File s
I n pu t /
W r it t e n by Re a d by Con t e n t s
Ou t pu t File s
Job.twp AdvantEdge AdvantEdge Simulation geometry and

parameters
Job.inp AdvantEdge AdvantEdge Simulation parameters

engine
Job_wp.twm AdvantEdge AdvantEdge Workpiece and tool

Job_tool.twm engine material information
Job.tww AdvantEdge AdvantEdge Custom workpiece

engine geometry
Job.twt AdvantEdge AdvantEdge Custom tool geometry

engine
Job.twe AdvantEdge AdvantEdge Tool wear

engine
Job.out AdvantEdge User Diagnostic and progress

engine output from simulation
Job.twb AdvantEdge Tecplot Mesh and contour data

engine
Job_ft.tec AdvantEdge Force filter Tool force data

engine
Job.fft.tec Force filter Tecplot Filter tool force data
Job.par AdvantEdge AdvantEdge Meshing parameters

engine (3D only)
Job.par.out AdvantEdge User Diagnostic and progress

output from simulation
(3D only)
Job.ps Tecplot Printer Mesh and contour plotting

information
Job_fft.ps Tecplot Printer Time and tool force

plotting information
Job.zip AdvantEdge AdvantEdge Support files
15.2 — Job Monitor

After the simulation is submitted, AdvantEdge will run the simulation. Depending on the process
parameters, simulation running time may vary. The user can check the job monitor to determine
current simulations on this computer, the length of cut, total length of cut, the simulation status
and the approximate time left for the simulation to complete. The approximate simulation time is
estimated using the current length of cut and the elapsed time since the simulation has started.
222
This time will change as the simulation progresses and will become more accurate as the simulation
reaches a stable number of workpiece elements.
Fi g u r e 1 5 - 1 : A d v a n t Ed g e Jo b M o n i t o r W i n d o w
The job monitor will launch after submitting a simulation through the user interface. It can also be
opened by selecting Sim u la t ion > Job M on it or. The job monitor keeps a log of all simulations that
have been meshed or modeled on a computer and allows users to sort these jobs based on:
• O r d e r o f Su b m i ssi o n — latest submissions first

• P r o j e ct N a m e — alphabetically ascending order
• Cu r r e n t Le n g t h o f Cu t — ascending order
• T o t a l Le n g t h o f Cu t — ascending order
• Si m u l a t i o n St a t u s (Running, Stopped, Done, Waiting) — alphabetically ascending order
Users can select the criteria for sorting from the Sort By menu in the Job Monitor.
223
Fi g u r e 1 5 - 2 : A d v a n t Ed g e Jo b M o n i t o r w i n d o w w i t h So r t By m e n u d i sp l a y e d
The Job Monitor may also be used to open projects within Tecplot. To open a project from the Job
Monitor, select the project and click Jo b > O p e n or double-click on the project itself.
To stop, delete or view the results of a simulation in the job monitor, select the job in the job
monitor and right click to open a job specific options menu. The job can be opened in the user
interface, current results can be viewed, tje job can be deleted from the job monitor list (the files
will not be affected) or the job can be stopped, which will end the simulation progress.
Fi g u r e 1 5 - 3 : A d v a n t Ed g e Jo b M o n i t o r w i n d o w w i t h j o b sp e ci f i c o p t i o n s m e n u d i sp l a y e d
224
Runtime Error Codes
If any of the following errors are encountered within the Job Monitor, users should create a project
archive file (see Support/Archive Files Feature), email Third Wave Systems at
support@thirdwavesys.com, and attach both the project archive file and error code number.
Ta ble 1 5 .2 : Ru n t im e Er r or Code s a n d Associa t e d Use r M e ssa ge s
Er r or Code Use r M e ssa ge
0001 File I/O Error
0002 File parsing error
0003 License check error
0004 Restart file does not exist or wrong format
0005 Memory shortage
0006 Reached maximum number of materials
0007 Tool material is not defined
0008 Error in assigning beam material properties
0009 Error in steady state thermal boundary condition input
0010 Unsupported process type
0011 Memory shortage for AE2D meshing
0012 Tool materials error
0013 Invalid tool material ID
0014 Path/file name too long
0015 Error maximum number of nodes needs to be increased

1001 Bad element
1002 Incorrect element number in set_subc_
1003 Incorrect time step length
1004 Tool element collapsed
1005 Force computation error
2001 High temperature
3001 Bad element
4001 Mesh distortion
4002 Contact adjustment error
4003 Tool tip contact adjustment error
4004 Coordinate instability
4005 Velocity instability
5001 Contact surface error
225
Should the user try to trouble-shoot the error individually, the following are some possible
explanations:
• Er r o r co d e 0 0 0 1 occurs when a necessary file for running a simulation is missing. This can
happen when the user has copied simulation files to a new directory and a required file was
forgotten. The user can check the directory in which the simulation file is stored to verify that
all the necessary files exist. To correct, open the given simulation in AdvantEdge and re-save
(see Saving Simulation Files). AdvantEdge should write the missing file or re-write the
incorrect file.
• Er r o r co d e 0 0 0 2 occurs when an input file is modified incorrectly, such as when the user
modifies an input file outside of AdvantEdge and accidentally deletes a file line. To correct,
open the simulation in AdvantEdge and re-save. AdvantEdge should write the missing file or
re-write the incorrect file.
• Er r o r co d e 0 0 0 3 requires the user to contact Third Wave Systems to ensure that the
proper license file has been provided.
• Er r o r co d e 0 0 0 4 requires the user to verify that the simulation restart file
(projectname_bak.res) exists within the simulation directory.
• Er r o r co d e 0 0 0 5 requires the user to increase the number of nodes in the simulation to
increase the memory allocated to running that simulation (2D only). This is done by selecting
Si m u l a t i o n > Si m u l a t i o n O p t i o n s and accessing the General tab. It is recommended
that the user first try and double the number of nodes and re-run the simulation. If this error
is encountered while running a 3D case, the user should contact Third Wave Systems.
• Er r o r co d e s 0 0 0 6 , 0 0 0 8 , 0 0 0 9 , 4 0 0 2 , and 5 0 0 1 require the user to contact Third
Wave Systems. A possible fix for error 5001 is to change the mesh refinement and mesh
coarsening factors by selecting Si m u l a t i o n > Si m u l a t i o n O p t i o n s > W o r k p i e ce
M e sh i n g . The default parameters for mesh refinement and mesh coarsening are set to 2
and 6, respectively. The user can try to set these to 4 and 4, to make the mesh more refined;
this has been known to clear this error.
• Er r o r co d e 0 0 0 7 requires the user to open the simulation in AdvantEdge and re-save.
AdvantEdge should write the missing tool file or rewrite the file if it is incorrect.
• Er r o r co d e 0 0 1 0 occurs when the input file (*.inp) is modified and AdvantEdge does not
recognize the process (such as milling, turning, etc.). This would occur if the process was
misspelled or the process line was deleted. The user can re-save the file so that the input file
is rewritten correctly.
• Er r o r co d e s 1 0 0 1 , 2 0 0 1 , 3 0 0 1 and 4 0 0 1 are errors specific to the way AdvantEdge has
meshed the tool and workpiece. There are a few different ways that these errors could be
fixed: the user could increase the tool radius when defining tool geometry, altering the mesh
and making the simulation computationally easier; or the mesh parameters could be
decreased to make the tool and workpiece meshes finer.
 2D Meshing Options
 3D Meshing Options
226
Sim u la t ion M a n a ge m e n t | Lice n se M on it or
15.3 — License Monitor

To open the Third Wave License Monitor, the user can click the Lice n se M on it or button within the
Simulation Options window, or they can select St a r t > All Pr ogr a m s > Th ir d W a ve Adva n t Edge
> Lice n se M a n a ge m e n t > Lice n se M on it or .
This window provides information about which features from the license are currently checked out.
The user is able to see the license keyword, version, maximum available (cores/seat), currently
available (cores/seat), expiration, host name, user name, number in use (cores/seat), and checked
out (date and time). It is beneficial to know this information before selecting cores for a simulation.
If multiple people use one network license, it is also beneficial to determine who is utilizing the
license.
To sort the table, simply click on the header for the column you wish to sort by. For example, to
sort by feature, use the mouse to click Feature in the Third Wave License Monitor. The arrow that
appears will show which column the table is sorted by and if it is ascending or descending. To
toggle between ascending and descending, select the header again. The arrow should switch from
down to up or up to down and the table will sort accordingly.
Fi g u r e 1 5 - 4 : T h i r d W a v e Li ce n se M o n i t o r sh o w i n g a Se r i a l Ex e cu t i o n Co u n t e d Li ce n se w i t h
t w o se a t s
The features listed will vary depending on the user’s type of license. In 2014 a new flexible
licensing scheme became available to the user. Contact sales@thirdwavesys.com for more
information.
227
Fi g u r e 1 5 - 5 : T h i r d W a v e Li ce n se M o n i t o r sh o w i n g Fl e x i b l e Li ce n si n g w i t h 4 0 co r e s
228
Ta ble 1 5 .3 : Lice n se M on it or D e scr ipt ion s
Fe a t u r e Th ir d W a ve Lice n se M on it or D e scr ipt ion
ae_tecplot Tecplot License: Shows the number of Tecplot license

seats that the user has and is utilizing
ae2d_xxcores 2D parallel (Execution counted): This shows the
number of 2D license seats that are available or in use
for any user that has not upgraded to flexible licensing.
A number will appear in place of the xx in the feature
name stating how many cores a simulation is
permitted to run.
ae3d_xxcores 3D parallel (Execution counted): This shows the

number of 3D license seats that are available or in use
for any user that has not upgraded to flexible licensing.
A number will appear in place of the xx in the feature
name, stating how many cores a simulation is
permitted to run.
ae3d_mesh 3D Mesher: Shows the 3D Mesher license seats that
the user could and is utilizing
ae_hpc HPC client: This appears if the user has purchased the
HPC upgrade
ae_flex Flexible License Count Limiter: This appears if the user
has upgraded to Flexible Licensing. The number of
cores will be displayed so the user knows the
maximum available, the number of cores currently
available, and the number of cores in use. If the user
has both 2D and 3D, they will both pull from the same
number of maximum available. Every time a
simulation is run with flexible licensing another row
will be added to the monitor to allow the user to see
availability and usage information. Only the first
incidence of this keyword will show the maximum and
currently available cores.
ae2d_flex 2D Flexible License: Simply shows that 2D feature is
active with the flexible license being used. This row in
the License Monitor will not display any numbers
because ae_flex will display all the 2D and 3D Flexible
Licensing information.
ae3d_flex 3D Flexible license: Simply shows that 3D feature is
active with the flexible license being used. This row in
the License Monitor will not display any numbers
because ae_flex will display all the 2D and 3D Flexible
Licensing information.
N ot e : In 2014 it is expected that a new version of Production Module will be released and
the license monitor will also work for the new version of Production Module in addi-
tion to AdvantEdge. These features will be described in the Production Module user
229
Sim u la t ion M a n a ge m e n t | Fle x ible Lice n sin g
manual when this becomes available and the features will start with pm instead of
ae.
15.4 — Flexible Licensing

Flexible Licensing is an upgrade available for AdvantEdge. It provides the user more flexibility by
breaking the license up by core count instead of execution. With this capability users are able to
get greater through-put in order to quickly solve problems. For more information or to purchase
this upgrade, contact sales@thirdwavesys.com.
Submitting a Single Simulation
To submit a single simulation project, select Si m u l a t i o n > Su b m i t > Su b m i t Cu r r e n t Jo b .

The Submit Simulation window will open. With N e w Jo b selected, click O K to start the simulation.
The Job Monitor will automatically open to show the progress of the job.
Fi g u r e 1 5 - 6 : Su b m i t Si m u l a t i o n w i n d o w
Fi g u r e 1 5 - 7 : T h i r d W a v e A d v a n t Ed g e Jo b M o n i t o r w i n d o w
230
Submitting a Batch Job
Batch jobs trigger several simulations to run in series rather than in parallel; when one is
completed, another will automatically begin. To submit a batch job, select Si m u l a t i o n > Su b m i t
> Su b m i t Cu r r e n t Jo b . The Job Monitor will automatically open to show the progress of the
current job and any job that has completed.
• Saving Batch Files
Fi g u r e 1 5 - 8 : Su b m i t Ba t ch Jo b w i n d o w
N ot e : For Windows operating systems, batch jobs can be submitted from the user inter-
face, a DOS prompt, or Windows Explorer by double-clicking on the batch file.
Users opting to double-click the batch file to start the batch job should not close the
command prompt that will be opened; otherwise, the entire batch will be termi-
nated. If a DOS prompt does not automatically open, there is something wrong with
the simulation; check the *.out file.
I N I TI AL M ESH GEN ERATI ON ( 3 D ON LY)
Once a 3D simulation has been submitted (for more, see Flexible Licensing is an upgrade available
for AdvantEdge. It provides the user more flexibility by breaking the license up by core count
instead of execution. With this capability users are able to get greater through-put in order to
quickly solve problems. For more information or to purchase this upgrade, contact
sales@thirdwavesys.com). AdvantEdge will begin generating the initial mesh for the project. The
Job Monitor will automatically open to show the progress of the job. After AdvantEdge completes
this initial mesh generation, the Meshing Complete window will open, alerting the user that the
simulation is ready to be run.
231
Fi g u r e 1 5 - 9 : M e sh i n g Co m p l e t e w i n d o w
• If the user clicks Su b m i t N o w , AdvantEdge will submit the batch file immediately. The job,
along with its status, should appear in the Job Monitor within a few seconds. In rare cases,
the job may not automatically start. If this occurs, submit the job by double clicking on the
batch file within the Job Monitor.
• If the user clicks Su b m i t La t e r, AdvantEdge will create a batch file to be submitted at the
user’s convenience. The location of this batch file will appear in the Submission Help window,
which opens when Submit Later is clicked. The job will still appear in the Job Monitor, but the
status will be listed as Waiting for Submission.
Fi g u r e 1 5 - 1 0 : Su b m i ssi o n H e l p w i n d o w
• If the user clicks V i e w M e sh , a Tecplot window will display the initial mesh generated. Once
the user is finished viewing the mesh, the Tecplot window can be closed. Upon returning to
AdvantEdge, either Submit Now or Submit Later must be clicked from the Meshing Complete
window.
N ot e : Cases may experience meshing problems in AdvantEdge for a variety of reasons. To

diagnose the meshing problem, please reference the AdvantEdge Mesh Error Code
List.
232
Sim u la t ion M a n a ge m e n t | St oppin g a n d Re st a r t in g Jobs
15.5 — Stopping and Restarting Jobs
Stopping a Job
A job can be stopped at any time by opening the Job Monitor window, highlighting the job to be
terminated, and then clicking either D e l e t e or St o p from the Job menu.
Restarting a Single Simulation
Jobs may have stopped because:
• User interrupted processing prior to completion

• Power outage, full disc drive, etc.
If further processing is desired, a single simulation may be restarted by selecting Si m u l a t i o n >

Su b m i t Cu r r e n t Jo b , then activating the R e st a r t radio button. Restarted jobs require a re-start
file with the extension *.res.
Prior to restarting the simulation, users can make changes to the project. These changes include
anything within the Simulation Options window (see 2D Simulation Options or 3D Simulation
Options). However, the tool, workpiece, and process parameters may not be changed, with the
exception of the length of cut, which can be increased/decreased.
N ot e : Any job that has been restarted will show up in the Job Monitor with the correct
length of cut and current information.
Restarting a Batch Job
Restarting a batch job is more difficult than Restarting a Single Simulation, but may be necessary
due to a power loss or computer reboot. To restart a batch job from where things terminated:
1. Select Si m u l a t i o n > Ba t ch Fi l e > Cr e a t e / Ed i t Ba t ch Fi l e

2. Browse for batch file and then locate the last simulation that was running when the batch
was stopped. Restarted jobs require a restart file, with the extension *.res.
3. Highlight every job above this line and D e l e t e them
4. Sa v e the file
5. Open the stopped simulation by selection Si m u l a t i o n > Su b m i t Cu r r e n t Jo b
6. Activate the R e st a r t radio button
233
Sim u la t ion M a n a ge m e n t | Su ppor t / Ar ch ive File s Fe a t u r e
N ot e : Users are strongly encouraged to back up all files before attempting a batch restart.
An easy suggestion is to create a new folder within the same directory and copy all
files to this folder.
Opening Current Zone in Tecplot
The Job Monitor can open the current zone for any simulation that has completed or is currently
running. This allows the user to see the current status of the simulation, which can help analyze a
simulation’s progress. To use this option,
1. Open the Job Monitor by selecting Si m u l a t i o n > Jo b M o n i t o r.

2. Within the Job Monitor window, select the desired simulation to analyze (the simulation
will be highlighted in blue when selected).
3. Select Jo b > V i e w Cu r r e n t Z o n e
4. Right-click on the selected job and choose to view the current zone. Tecplot will automat-
ically open the simulation, displaying only the current zone.
Fi g u r e 1 5 - 1 1 : T h i r d W a v e A d v a n t Ed g e Jo b M o n i t o r w i n d o w w i t h V i e w Cu r r e n t Z o n e f e a t u r e
se l e ct e d f r o m Jo b m e n u
15.6 — Support/Archive Files Feature

Users encountering problems with AdvantEdge or looking for Third Wave Systems to review a
project will be required to archive files before sending them to Third Wave. Archiving is also useful
for saving on storage space.
The AdvantEdge archiving feature packages all the files needed for error diagnosis and future use.
To archive a project, select P r o j e ct > A r ch i v e > Cr e a t e A r ch i v e Fi l e . The project will be
saved as a zipped file, allowing for easy transmission when emailing.
When manually archiving project files, not all files created by AdvantEdge are needed. The following
files are required for future simulation viewing and re-creation; all other files may be deleted:
Projectname.twp
projectname.inp
projectname.tww
projectname.twt
234
Sim u la t ion M a n a ge m e n t | Con ve r t in g t o Bin a r y File s
projectname_wp.twm
projectname_tool.twm
projectname_beam.twm
projectname.twb
projectname_ft.tec
If coatings are used:
projectname_coat1.twm
For STEP/STL/NASTRAN Import:
Projectname.stp
Filename.stl
Filename.nst
Other Files:
projectname.tws
projectname.twe
projectname.par
15.7 — Converting to Binary Files

*.tec files are originally in ASCII format and can take up a lot of space. However, these files can be
converted to Binary contour file format (*.twb), which requires less disk space. To convert files to
Binary contour file format:
1. Go to St a r t > R u n . For Windows NT/2000/XP, type ‘cmd.’

2. Browse to the folder where files are saved (cd [Path to Folder])
3. Type ‘dir*.tec’ to display the TEC files
4. Type the command ‘preplot [input file] [output file] –zonelist 1:[Large Number]:[Zone
Skip number]’ to XXXXX
(for example, preplot example.tec example_preplot.tec –zonelist 1:50:2). This process may
take several minutes.
5. Go to [Drive Letter]:\ThirdWaveSystems\AdvantEdge\advantpost\bin and double-click on
advantpost.exe to load the files in Tecplot
6. Within Tecplot, select Fi l e > Lo a d D a t a Fi l e s. Browse for the created file and open it.
To view converted binary format contour files, select Si m u l a t i o n > R e su l t s or see Contour Files.
235
CHAPTER 16 — RESULTS ANALYSIS:
TECPLOT
AdvantEdge utilizes Tecplot software to display and assist in analyzing simulation results. Tecplot
can create Contour Plots, Mesh Plots, Vector Plots, XY Plots, and Animation Plots of the simulation
results. Information necessary for viewing AdvantEdge results in Tecplot are included herein;
additional information on Tecplot may be found in the Tecplot User’s Manual by selecting St a r t >
A l l P r o g r a m s > T h i r d W a v e Sy st e m s A d v a n t Ed g e > D o cu m e n t a t i o n > T e cp l o t U se r ’ s
M a n u a l.
Fi g u r e 1 6 - 1 : T e cp l o t w i n d o w d i sp l a y i n g A d v a n t Ed g e r e su l t s
235
Re su lt s An a lysis: Te cplot | St a r t in g a n d St oppin g Te cplot
16.1 — Starting and Stopping Tecplot

Tecplot contains a standard window and command panel with commonly-used display options. The
software can be automatically initialized by selecting Si m u l a t i o n > R e su l t s from within
AdvantEdge. Tecplot will initially display Contour Plots of temperature and XY Plots of cutting forces
reflecting the current job open in AdvantEdge.
To stop Tecplot, click Q u i t on the command panel or select Fi l e > Ex i t in Tecplot.
16.2 — AdvantEdge Results Files

AdvantEdge writes two types of results files during a simulation: Contour Files and Force Files.
Contour Files
Contour files are written as [projectname].twb. These files contain results data used for creating field
plots such as Contour Plots, Mesh Plots, Vector Plots and Animation Plots.
Contour file data set in Tecplot is divided into zones corresponding to states of the chip/workpiece/
tool model at certain instances of time. Contour files are composed of [n+1] zones, where n is the
number of frames at which the model is written during the simulation. An extra first frame is
written as the original state of the model.
Force Files
Force files contain time history data of the tool cutting and transverse forces. Forces are plotted in
XY Plots. To create these files, AdvantEdge first writes files called [projectname]_ft.tec. These files
consist of raw force data fed into a filter program to remove high frequency noise from the data.
Filtered forces are then written as [projectname]_fft.tec, which include time history data of the tool
cutting and transverse forces.
16.3 — Contour Plots

Contour plots display the spatial distribution of a field variable over the model, such as the
temperature over the tool/chip/workpiece region.
To activate contour plots, check the Co n t o u r checkbox located on the Tecplot sidebar. To turn off
the mesh layer using the sidebar, select the contour plot window and uncheck the M e sh checkbox
(the contour plot window must be selected for this option to appear).
236
Re su lt s An a lysis: Te cplot | Con t ou r Plot s
It is recommended that users utilize the M e sh button within the Contour Tab of the AdvantEdge
Quick Analysis window to toggle the mesh on and off.
Contour Variables
The available contour variables for Contour Plots in Tecplot are listed below. Variable units are in
parentheses; first in SI, then in English.
Ta ble 1 6 .1 : Con t ou r Va r ia ble s Ava ila ble in Te cplot
Va r ia ble D e scr ipt ion
Temperature* Temperature (ºC | ºF)
Heat Rate Heat generation due to plastic strain (W/mm3 | Hp/in3)
Plastic Strain Effective plastic strain (dimensionless)
Plastic Strain Rate Effective plastic strain rate (1/s | 1/s)
Mises Stress Von Mises stress (MPa | Psi)
Pressure Pressure stress (tensile is negative) (MPa | Psi)
Max Shear Stress Maximum shear stress (MPa | Psi)
Stress-XX XX stress component (MPa | Psi)
Stress-YY YY stress component (MPa | Psi)
Stress-ZZ ZZ stress component (MPa | Psi)
Max Principal Maximum principal stress (MPa | Psi)
Min Principal Minimum principal stress (MPa | Psi)
Velocity Magnitude Total velocity magnitude (m/min | ft/min)
Tool/Workpiece Tool is yellow

Contrast Workpiece is green
Boundary Boundary conditions displayed in red

Conditions Non-boundary conditions displayed in blue
*The default Tecplot contour variable is Temperature. To change the contour variable, either:
• Pick the contour option from the Plot menu and then choose the desired variable from the
Current Variable dropdown, or select T o o l s > A d v a n t Ed g e A n a l y si s.
• Select T o o l s > A d v a n t Ed g e A n a l y si s and then choose the desired contour from the
Select Contour dropdown menu.
Contour Zone Style
To change certain properties of Contour Plots, double-click on the tool/workpiece model to open the
Zone Style window. The most useful attributes to change are zone show, cont show, and contour
type.
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Re su lt s An a lysis: Te cplot | M e sh Plot s
Zone Selection
When Tecplot initially opens, all zones are activated and displayed. To deactivate certain zones for
Contour Plots, double-click on the model to open the Zone Style window. Click and drag desired
zones into the zone list area of the Zone Style window, then select D e a ct i v a t e from the Zone
Show dropdown menu.
Contour Type
To change the contour type for Contour Plots, click the Z o n e St y l e button within the AdvantEdge
Quick Analysis window or double-click on the tool/workpiece display. The Zone Style window will
open. Click and drag desired zones into the zone list area of the Zone Style window, then click the
Co n t P l o t T y p e button and choose a new contour type. The most common contour type is Flood.
Contour Legend and Contour Levels
To adjust legends and levels for Contour Plots, select P l o t > Co n t o u r / M u l t i - Co l o r i n g … The
Contour & Multi-Coloring Details window will open.
Within the Levels tab of the Contour & Multi-Coloring Details window, select N e w Le v e l s. Specify
the minimum level, maximum level, and number of levels.
Within the Legend tab of the Contour & Multi-Coloring Details window, check the Sh o w Co n t o u r
Le g e n d checkbox, then close the window.
On the Tecplot sidebar, click R e d r a w A l l to view the contour plot with a contour legend. To
position the contour legend properly, click on the contour legend and drag it to the proper position.
16.4 — Mesh Plots

Tecplot mesh plots display the deformed finite element meshes of the simulation model. Areas with
fine mesh refinement indicate the most active regions of deformation and contact.
To activate the mesh plot feature in Tecplot, check the M e sh checkbox located on the Tecplot
sidebar.
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Re su lt s An a lysis: Te cplot | Ve ct or Plot s
Mesh Attributes
To open the Mesh Attributes window for Mesh Plots, double-click on the model. The most useful
attributes to change are Zone Show (to select the plot zones to activate/deactivate) and Mesh Color
(to specify the mesh color of the various zones).
Fi g u r e 1 6 - 2 : T e cp l o t m e sh p l o t
16.5 — Vector Plots

Tecplot vector plots are used to display a vector variable in the form of arrows indicating both
direction and magnitude of the vector variable throughout the model. In simulations, vector
components of interest are the velocity components (velocity-X and velocity-Y), as these plots
indicate the flow rate of the material.
To activate vector plots, check the V e ct o r La y e r checkbox on the Tecplot sidebar and, if
necessary, deselect other plot type layers. Specify the U and V vector components. In AdvantEdge
simulations, these are velocity components Velocity-X and Velocity-Y.
Vector Plot Attributes
To open the Vector Plot Attributes window for Mesh Plots, double-click on the model. The most
useful attributes to change are Zone Show (to select the plot zones to activate/deactivate) and
Vector Color (to specify the vector colors of the various zones).
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Re su lt s An a lysis: Te cplot | XY Plot s
Fi g u r e 1 6 - 3 : T e cp l o t v e ct o r a n d st r e a m t r a ce p l o t o f v e l o ci t y
16.6 — XY Plots
Tecplot XY plots are commonly used to display the time histories of variables. For AdvantEdge, the
variables of greatest interest are the cutting force (FX) and transverse force (FY) on the tool. These
variables are displayed as functions of time.
To activate XY plotting, select T o o l s > A d v a n t Ed g e A n a l y si s and click the X and Y Force plots
options within the Time History tab.
XY Plot Attributes
To open the XY Mapping Style window for XY Plots, double-click on an XY curve. The most useful
attribute to change is Map Show (to select the curves to activate/deactivate).
Curve Fitting
The file job_fft.tec contains AdvantEdge filtered force data with high frequency components
removed from the raw force data. Clicking the Fo r ce Fi l t e r button within the Display Options tab
of the AdvantEdge Quick Analysis window will instruct Tecplot to fit a tenth order polynomial to the
already filtered data.
Tecplot can also generate custom curves to further smooth and better fit the filtered force curves of
XY Plots. To create a custom curve fit:
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Re su lt s An a lysis: Te cplot | An im a t ion Plot s
1. Double-click on a curve to bring up the XY Mapping Style window

2. Duplicate a curve by choosing the Create Map option. To specify the Y-axis variable,
choose FX or FY. The X-axis variable is time.
3. Click Cu r v e s and select a PolyFit curve type
4. Click Cu r v e s and select PolyOrder to choose a polynomial order (6 or more recom-
mended)
5. Close the XY Mapping Style window and click R e d r a w in the Tecplot sidebar to see the
curve fit overlaying the original curve
Fi g u r e 1 6 - 4 : T e cp l o t X Y p l o t o f cu t t i n g a n d t r a n sv e r se f o r ce s w i t h cu r v e f i t t i n g
16.7 — Animation Plots

Animation involves displaying a succession of still images to give the impression of motion. There
are multiple methods for generating an animation in Tecplot; the most common methods are
discussed below. Additional methods are discussed within the Tecplot User’s Manual.
AdvantEdge Quick Analysis
The recommended method for creating Animation Plots within Tecplot is to use the AdvantEdge
Quick Analysis window. To open the AdvantEdge Quick Analysis window, select T o o l s >
A d v a n t Ed g e A n a l y si s.
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Re su lt s An a lysis: Te cplot | An im a t ion Plot s
Fi g u r e 1 6 - 5 : A d v a n t Ed g e Q u i ck A n a l y si s w i n d o w
Animate Menu
To open the Animate menu within Tecplot, select A n i m a t e > A n i m a t e Z o n e s.
The A n i m a t e button will animate the current view from the Start Zone to the End Zone. If a vast
number of zones are present, the user may increase the Zone Skip value to speed up the
animation. However, as the Zone Skip value increases, the simulation becomes choppier.
The user can also step through the animation frame by frame. This is done by clicking on the up
and down arrows located to the right of the current zone information.
Fi g u r e 1 6 - 6 : A n i m a t e Z o n e s w i n d o w
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Re su lt s An a lysis: Te cplot | Zon e Se le ct ion Tool
Creating AVI/RM Files
Animation files, including AVI and RM files, can be displayed as videos outside Tecplot. AVI files are
considered standard Windows movie files, and can easily be added to PowerPoint presentations or
Word documents. AVI files have a 2 GB size limit. RM files are highly compressed, real media files.
To create a video file, open the Animate Zones window within Tecplot by selecting A n i m a t e >
Z o n e s. From the Animate dropdown menu, select the animation format desired (AVI or RM) and
click the A n i m a t e button. Users will be prompted to define the animation region, image width, and
animation speed. The video file will be created and saved as the user directed.
Fi g u r e 1 6 - 7 : Ex p o r t w i n d o w f o r a n i m a t i o n e x p o r t
16.8 — Zone Selection Tool

When simulation results are larger than 500 MB or greater than 100 zones, AdvantEdge will prompt
the user to utilize the Zone Selection tool to open the results. This will allow the user to pick certain
zones to view instead of loading the entire file into Tecplot. This feature is especially useful when
running a wear model simulation (many zones generated) or a simulation with a dense mesh (many
elements generated) such as Residual Stress Analysis, as the results file will require a large amount
of memory.
• 2D Tool Wear
• 3D Tool Wear
Fi g u r e 1 6 - 8 : Z o n e Se l e ct i o n t o o l p r o m p t
243
Re su lt s An a lysis: Te cplot | Zon e Se le ct ion Tool
If the user opts to not use the Zone Selection tool, Tecplot will attempt to load the results file in its
entirety.
If the user chooses to utilize the zone selection tool, a blank Tecplot screen will load. The user must
then select Fi l e > Lo a d D a t a Fi l e and choose the AdvantEdge Loader.
Fi g u r e 1 6 - 9 : Se l e ct I m p o r t Fo r m a t w i n d o w w i t h A d v a n t Ed g e Lo a d e r se l e ct e d
Within the AdvantEdge Loader window, click the Se l e ct button and browse to the appropriate
results file (*.twb extension). Check the Z o n e Se l e ct i o n checkbox at the lower righthand corner
of the AdvantEdge Loader window to activate the Zone Selection button.
Fi g u r e 1 6 - 1 0 : A d v a n t Ed g e Lo a d e r w i n d o w
The user can then click the Z o n e Se l e ct i o n button to open the Zone Selection window. All
available zones in the simulation results file, along with corresponding simulation times during
which they occur, will be listed on the left side of the Zone Selection window. Zones to be displayed
in Tecplot can be added by highlighting the zone and clicking the A d d button. Zones can be
244
Re su lt s An a lysis: Te cplot | Pr in t in g Plot s
removed by highlighting them in the right box and clicking R e m o v e . All zones listed on the right
side of the window will be displayed in Tecplot.
Fi g u r e 1 6 - 1 1 : Z o n e Se l e ct i o n w i n d o w
16.9 — Printing Plots
Printing to a File or Printer
Users can choose to print directly from Tecplot to a printer, or print from Tecplot to a file.
To print a plot, select Fi l e > P r i n t . Within the Print window, specify whether to send the output
directly to a printer, or to a file. If the Se l e ct O u t p u t t o Fi l e checkbox is checked, the Print to a
File window will open to allow for filename specification of the plot file.
Print Format
To manipulate the Tecplot print format, open the Print Setup window by either clicking the P r i n t
Se t u p button from the Print window (Fi l e > P r i n t ) or selecting Fi l e > P a p e r Se t u p .
16.10 — Extracting Data
Probing for Values
Tecplot has the capability to extract data from any specific point in the field or force plot. To do this,
click the Probe tool ( ) from the top Tecplot toolbar, or select D a t a > P r o b e A t . The probe tool
245
Re su lt s An a lysis: Te cplot | Ex t r a ct in g D a t a
allows users to click on the specific point of interest within the field/force plot to display a value for
all calculated variables at that specific location. The Probe At option allows users to select a specific
point based on an X and Y coordinate value.
N ot e : Probing in an area where the tool and workpiece overlap could cause confusion. In
Tecplot, the tool will be displayed on top of the workpiece; however, the probe value
displayed at that location will be for the workpiece.
Extracting Polylines
Extracting data by way of a polyline allows users to draw lines on the field plot that can be divided
into a specified number of points. The numerical data acquired from these points can be saved to a
file or new Tecplot zone. Using this data, plots can be created from any available variables.
To extract a polyline, click the Ex t r a ct a P o l y l i n e o f P o i n t s button within Tecplot. Move the

mouse to a desired location and click the beginning and end points for the line. The polyline can be
one straight line or a series of line segments. Once the polyline is complete, right-click to complete
the polyline.
The Extract Data Points window will automatically open, allowing the user to extract data to a file or
a new Tecplot zone. In addition, this window also allows the user to specify the number of points
extracted along the polyline, with the option to include the distance variable. The distance variable
specifies the distance from the starting point of the polyline to each point in the polyline. After all
selections are complete, click Ex t r a ct .
Fi g u r e 1 6 - 1 2 : Ex t r a ct D a t a P o i n t s w i n d o w
If the data is extracted to a file, the file needs to be opened using Tecplot in order to analyze the
data. To load the file into Tecplot, select Fi l e > Lo a d D a t a Fi l e . The Select Initial Plot window will
open. From the Initial Plot Type dropdown menu, choose the X Y l i n e option. Then click the O K
button. In order to view the specific plots, the user should use the Mapping Style menu and click
the R e d r a w button.
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Re su lt s An a lysis: Te cplot | Use r - D e fin e d Ou t pu t Va r ia ble s
Fi g u r e 1 6 - 1 3 : Se l e ct I n i t i a l P l o t w i n d o w
16.11 — User-Defined Output Variables

Tecplot allows users to define output variables to be displayed in the simulation contour plot. This
option often results in faster loading of contour files due to fewer variables selected for display. To
use this feature, select Fi l e > Lo a d D a t a Fi l e and select the AdvantEdge Loader.
Fi g u r e 1 6 - 1 4 : Se l e ct I m p o r t Fo r m a t w i n d o w w i t h A d v a n t Ed g e Lo a d e r se l e ct e d
Within the AdvantEdge Loader window, click the Se l e ct button and browse to the appropriate
results file (*.twb extension). Specify the variables to be displayed in Tecplot by checking the boxes
for variables of interest.
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Re su lt s An a lysis: Te cplot | Re sidu a l St r e ss Volu m e Ave r a gin g ( 3 D on ly)
Fi g u r e 1 6 - 1 5 : A d v a n t Ed g e Lo a d e r w i n d o w
16.12 — Residual Stress Volume Averaging (3D only)

The Residual Stress Volume Averaging feature within AdvantEdge provides a residual stress
prediction that mimics X-ray diffraction test data. Stress over an area is averaged as a function of
depth into the workpiece surface. To use this feature, users must first set up and run a simulation in
AdvantEdge with the Residual Stress Analysis option selected.
Users will need to define a depth, orientation and diameter (corresponding to a beam diameter) to
be averaged. Once the simulation has been completed and the resulting *.twp file is opened in
AdvantEdge, activate the Residual Stress Volume Averaging feature by selecting Si m u l a t i o n >
R e si d u a l St r e ss V o l u m e t r i c A v e r a g i n g .
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Fi g u r e 1 6 - 1 6 : R e si d u a l St r e ss V o l u m e t r i c A v e r a g i n g w i n d o w
Within the Residual Stress Volumetric Averaging window, a beam length and orientation must be
specified. Beam orientation is then calculated by considering the angle of the beam vector with
respect to the Z-axis, and the angle of projection for the beam vector on the XY plane with respect
to the X-axis. Specify beam/extraction vector origin, diameter of X-ray beam, number of slices of X-
ray beams, and number of scan points per slice.
Fi g u r e 1 6 - 1 7 : A n g l e s f o r b e a m d e f i n i t i o n
Once all information has been entered, AdvantEdge will run the residual stress volume averaging
process and automatically open Tecplot to plot stress as a function of distance along the beam
length.
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Fi g u r e 1 6 - 1 8 : St r e ss X X v s D e p t h p l o t i n T e cp l o t
Fi g u r e 1 6 - 1 9 : St r e ss X X v s D e p t h p l o t i n T e cp l o t
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Re su lt s An a lysis: Te cplot | An a lyzin g Tool St r e sse s a n d Te m pe r a t u r e H ist or y a t Use r - Spe c-
ifie d Ele m e n t s ( 2 D on ly)
16.13 — Analyzing Tool Stresses and Temperature

History at User-Specified Elements (2D only)
When elements are selected within the Tool Mesh Viewer of AdvantEdge before running a 2D
simulation, tool stresses and temperature history data can be analyzed in Tecplot. Once a
simulation has run, click the El e m e n t s button within the Tecplot AdvantEdge AdvantEdge Quick
Analysis window (T o o l s > A d v a n t Ed g e Q u i ck A n a l y si s) to open the Select Elements to
Display window.
Within the Select Elements to Display window, users can plot stress components, Von Mises
stresses, and temperatures averaged over the selected elements.
Selecting a Variable
To select a variable for Analyzing Tool Stresses and Temperature History at User-Specified Elements
(2D only), first select the desired region from the Region dropdown menu. Region numbers are
originally defined within the Tool Mesh Viewer prior to running the simulation. To display a variable
on the plot, click the button with the appropriate variable name.
Users can plot Sigma-XX, Sigma-YY, Sigma-XY, Von Mises, Max Shear, Max Principal, Min Principal,
Pressure, and temperature. Each variable is an average over the user-defined region. To select all
variables, click the D i sp l a y A l l R e g i o n s a n d El e m e n t s button. To remove all selections, click
the Cl e a r A l l R e g i o n s a n d El e m e n t s button. The user can set the axis as either Left or Right
by clicking the corresponding radio button. Once the variables have been selected, click the O K
button to automatically populate the graph.
Fi g u r e 1 6 - 2 0 : Se l e ct El e m e n t s t o D i sp l a y w i n d o w
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Re su lt s An a lysis: Te cplot | An a lyzin g Tool St r e sse s a n d Te m pe r a t u r e H ist or y a t Use r - Spe c-
ifie d Ele m e n t s ( 2 D on ly)
Fi g u r e 1 6 - 2 1 : T i m e v s V o n M i se s St r e sse s f o r U se r - D e f i n e d El e m e n t s p l o t i n T e cp l o t
252
CHAPTER 17 — RESULTS UTILITIES:
TECPLOT
Third Wave Systems has added utilities to Tecplot in an effort to make the software more functional
for AdvantEdge users. These utilities automatically perform tasks and calculations that would
otherwise be performed by hand. Some examples are:
• R a k e a n d R e l i e f Fa ce D a t a Ex t r a ct i o n — allows the user to extract data from the rake

and relief face of the tool. Data includes forces, stresses, and temperatures. This feature can
also analyze multiple projects at once.
• R e si d u a l St r e ss Ex t r a ct i o n — allows the user to quickly extract data throughout a
section of the workpiece according to depth. The stresses and temperatures extracted are
used for residual stress analysis.
• M u l t i - P r o j e ct D i sp l a y — allows four contour plots or time history plots to be displayed at
one time.
• D a t a Se t A n a l y si s — allows the user to extract data from multiple simulations and analyze
the effects of rake, feed, and speed.
17.1 — AdvantEdge Quick Analysis

The AdvantEdge Quick Analysis window will open automatically when viewing results from
AdvantEdge in Tecplot. This utility is used to perform all the basic functions in Tecplot necessary for
viewing AdvantEdge results. To open the AdvantEdge Quick Analysis window at any time, select
T o o l s > A d v a n t Ed g e A n a l y si s.
There are two tabs within the AdvantEdge Quick Analysis window: Contour Tab and Time History
Tab. In addition, the window has a File Menu, View Menu, Data Menu, and Tools Menu.
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Re su lt s Ut ilit ie s: Te cplot | Adva n t Edge Qu ick An a lysis
Contour Tab
The Contour tab of the AdvantEdge Quick Analysis window can be used to select contour displays in
Tecplot. The user can decide to display the tool, workpiece, chip, and/or cutter body. The user can
also animate the contour plot, rotate the workpiece, measure a distance on the contour, or open the
Zone Style window using this tab.
Fi g u r e 1 7 - 1 : Co n t o u r t a b o f A d v a n t Ed g e Q u i ck A n a l y si s w i n d o w
• M e sh — toggles the mesh display on and off

• Se l e ct Co n t o u r — allows the user to Select Contour to display (temperature, stress XX,
pressure, etc.)
• Se l e ct V e ct o r — allows the user to Select Vector, plotting pressure, stress, shear stress,
temperature, nodal force, or velocity as vectors in the contour plot for 2D simulations
• T o o l — toggles the tool display on and off
• W o r k p i e ce — toggles the workpiece display on and off
• Ch i p — toggles the chip display on and off
• Cu t t e r Bo d y — toggles the cutter body display on and off
• A n i m a t e — steps through the frames sequentially to show the process as an Animation
• R o t a t e W o r k p i e ce — rotates the workpiece relative to the tool for 3D simulations. This
feature is only available for Milling and Drilling processes.
• M e a su r e D i st a n ce — allows the user to Measure Distance between two nodes on the
workpiece or tool
254
SELECT CON TOUR
The Select Contour dropdown menu within the AdvantEdge Quick Analysis Contour Tab allows the
user to select a contour parameter for the tool and workpiece. The different colors on the tool and
workpiece represent different levels of the selected parameter. This allows the user to perform a
wide range of analysis.
The user can display the following contours: temperature, heat rate, plastic strain, plastic strain
rate, Mises stress, pressure, maximum shear stress, stress XX, stress YY, stress ZZ, maximum
principal, minimum principal, velocity magnitude, tool/workpiece contrast, and boundary condition.
The user can view the tool and workpiece boundary conditions in Tecplot. By default, Tecplot will
load the boundary conditions for every project. To display these options, choose Bo u n d a r y
Co n d i t i o n s from the contour dropdown within the Contour Tab of the AdvantEdge Quick Analysis
window. When this contour type is selected, the contour will be contained to red and blue. The red
represents the boundary conditions for XY in 2D and XYZ in 3D. The blue represents no boundary
conditions.
Fi g u r e 1 7 - 2 : Bo u n d a r y co n d i t i o n s f o r 2 D a n d 3 D si m u l a t i o n s
N ot e : Depending on the mesh, the boundary may appear wavy, as displayed in the 2D
figure above. To show the boundary conditions, elements are shaded a specific
color.
SELECT VECTOR
The Select Vector option within the Contour Tab of the AdvantEdge Quick Analysis window allows
the user to plot pressure, stress, shear stress, temperature, nodal force, or velocity as vectors in
the contour plot for 2D simulations. The user can turn on the vector by using the Select Vector
dropdown menu. By default, this option will be turned off.
Vector selections are separate displays from those created from a Select Contour. These selections
allow the user to display a different vector than the contour selection. The user can also turn off
contour to display only the vector plot.
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Fi g u r e 1 7 - 3 : V e ct o r p l o t d i sp l a y s w i t h o u t ( l e f t ) a n d w i t h ( r i g h t ) co n t o u r d i sp l a y s
AN I M ATI ON
The A n i m a t i o n button within the Contour Tab of the AdvantEdge Quick Analysis window opens the
Animate Zones window. In this window the user can define the starting zone, ending zone, and
number of zones to skip during animation. Once the user has defined these values, click A n i m a t e
to watch the contour plot step through the defined zones.
Fi g u r e 1 7 - 4 : A n i m a t e Z o n e s w i n d o w
The user can also easily step through the zones manually by clicking the up and down arrows or
using the slider bar in the Animation Zones window.
M EASURE D I STAN CE
The Measure Distance option within the Contour Tab of the AdvantEdge Quick Analysis window
allows the user to measure the distance between two nodes on the workpiece or tool. To measure
distance, hold down the CTRL key and click in the approximate location of the first node. Continue
holding down the CTRL key and repeat for the second node.
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Time History Tab
The Time History tab of the AdvantEdge Quick Analysis window allows the user to define what
variables will be displayed on the time history plot, and on which axis. The user can also access this
tab to define Cut Off Frequency and Moving Average, select a polynomial fit, toggle between time
and length of cut, and open the Mapping Style window. This tab will also allow the user to view
selected Elements or Flutes, if the options were turned on during simulation setup.
Fi g u r e 1 7 - 5 : T i m e H i st o r y t a b o f A d v a n t Ed g e Q u i ck A n a l y si s w i n d o w
• Fo r ce X , Fo r ce Y , a n d Fo r ce Z , Fo r ce R a d i a l , Fo r ce T a n g e n t i a l — show the
designated force component on the time history plot. Radio buttons specify on which axis the
variables are plotted. The tangential and radial forces are based on the total resultant force.
The radia and tangential direction is determined dynamically at the centroid of the current
forces. The tangential force is tangent to the line between the center of the results (0,0) and
the centroid. The radial force is along this axis.
• P e a k T o o l T e m p — plots the temperature history of the highest temperature nodes on the
tool
• P o w e r a n d T o r q u e — plots the designated parameter on the time history plot
• T o o l St r e ss — shows an average stress over the time of the simulation
N ot e : This feature must be enabled during simulation setup within the Simulation Options
window of AdvantEdge (see Tool Stress).
• T o o l D e f l e ct i o n X , T o o l D e f l e ct i o n Y , a n d T o o l D e f l e ct i o n Z — plots deflection of
the tool over the time of the simulation
257
window of AdvantEdge (see Tool Deflection).
• Co n t a ct T r a ct i o n — plots components of contact traction in the normal and tangential

directions
• Co o l a n t T e m p — plots coolant temperature over time for internal, temperature-dependent
coolant cases. This operation does not exist for drilling or tapping cases.
• El e m e n t s — allows the user to see forces for selected elements
window of AdvantEdge (see Selective Element Plotting).
• Fl u t e s — allows the user to view cutting forces on each flute
window of AdvantEdge (see Cutting Forces for Each Flute).
• Cu t O f f Fr e q u e n cy o r M o v i n g A v e r a g e — allow the user to filter results

• A p p l y — allows the user to apply the cut off frequency or moving average to the time
history plot
• D e f a u l t Fr e q u e n cy — allows the user to go back to the default cut off frequency at any
time
• P o l y n o m i a l Fi t — allows the user to apply or remove a 10th order polynomial fit to the
time history plot
• T i m e / Le n g t h o f Cu t — toggles the X-axis between time and distance
• M a p p i n g St y l e — opens the Mapping Style window
CUT OFF FREQUEN CY AN D M OVI N G AVERAGE
By default, Tecplot will open the project by calculating the cut off frequency based on total time of
the simulation and display it in the cut off frequency text box. Once Tecplot is opened, the user can
choose to change the cut off frequency or apply a moving average. This may be helpful for Micro-
Machining or interrupted cut situations. To select moving average or cut off frequency, activate the
corresponding radio button and define the specific hertz or percentage. Click A p p l y to filter the
results. To return to the default cut off frequency, click the D e f a u l t Fr e q u e n cy button.
ELEM EN TS
The Elements button opens the Select Elements to Display window. This button will only be active
when the user has enabled this option in AdvantEdge before running the simulation (see Selective
Element Plotting).
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Fi g u r e 1 7 - 6 : Se l e ct El e m e n t s t o D i sp l a y w i n d o w
FLUTES
The Fl u t e s button opens the Select Flutes to Display window. This button will only be active when
the user has enabled this option in AdvantEdge before running the simulation (see Cutting Forces
for Each Flute).
Fi g u r e 1 7 - 7 : Se l e ct Fl u t e s t o D i sp l a y w i n d o w
File Menu
The AdvantEdge Quick Analysis File menu can be used when Opening a Project, Reloading
Simulation Results, Viewing the Current Zone, Exporting an AVI File, Exporting an Image, or
Resetting Preferences.
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OPEN I N G A PROJECT
To open a new project in Tecplot, select Fi l e > O p e n P r o j e ct from within the AdvantEdge Quick
Analysis window. Browse to the appropriate file and click O p e n . The user will be asked to confirm
that they wish to delete current results and load new results using the selected file. Click O K to
load the new results.
RELOAD I N G SI M ULATI ON RESULTS
Users can view results while a simulation is still running. While analyzing the results, the user can
reload the data to analyze more of the simulation. The current plot settings will remain when the
data is reloaded. To reload the data, select Fi l e > R e l o a d R e su l t s. Tecplot will automatically
reload the project that the user is viewing.
VI EW I N G TH E CURREN T ZON E
When a simulation is still running, it is sometimes useful to view the zone that the project is
currently in. This only loads one zone, which means there are not multiple zones to view or
animate. To view only the current zone in Tecplot, select Fi l e > V i e w i n g t h e Cu r r e n t Z o n e .
EXPORTI N G AN AVI FI LE
Tecplot allows the user to export a simulation as an AVI, for viewing outside of Tecplot. This AVI will
reflect the current plot/view in Tecplot. For example, if the user is only displaying a contour plot
with the workpiece displayed, then the exported AVI will be a contour plot with a workpiece. Once
the desired plot is displayed in Tecplot, select Fi l e > Ex p o r t from within the AdvantEdge Quick
Analysis window to export the AVI.
Fi g u r e 1 7 - 8 : Ex p o r t A V I Fi l e w i n d o w
Within the Export AVI File window, define the animation starting zone, ending zone, and number of
zones to skip, then click O K. Browse to the appropriate location where the file should be saved,
name the animation, and click Sa v e .
A green progress bar will display on the bottom of Tecplot while the AVI is being exported. This
progress bar will disappear when the export is complete.
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EXPORTI N G AN I M AGE
For external reports, the user may wish to export an image from Tecplot. This image may be
exported as a *.png, *.jpg, *.bmp, or *.tiff file. The exported image will reflect the current plot/
view in Tecplot.
To export an image from Tecplot, select Fi l e > Ex p o r t I m a g e from within the AdvantEdge Quick
Analysis window. Browse to the appropriate location where the file should be saved, name the
image, and click Sa v e .
RESETTI N G PREFEREN CES
The first time the AdvantEdge Quick Analysis Measure Distance tool is selected, a window will open
to explain how to use the feature. If the user checks the optional D o n ’ t sh o w t h i s w i n d o w
a g a i n checkbox, the window will no longer appear. To re-trigger the appearance of this window,
select Fi l e > R e se t P r e f e r e n ce s.
Fi g u r e 1 7 - 9 : A d v a n t Ed g e Q u i ck A n a l y si s h e l p w i n d o w f o r m e a su r i n g d i st a n ce
View Menu
The AdvantEdge Quick Analysis View menu allows the user to choose between displaying a contour
plot (see Contour Tab), time history plot (see Time History Tab), or both plots simultaneously. By
default, Tecplot will display both the contour and time history plots. The current view selection will
appear grey within the View menu.
Data Menu
The AdvantEdge Quick Analysis Data menu allows the user to change units and view project
information. Project information details are similar to what displays on the Project Information
sidebar within AdvantEdge.
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Fi g u r e 1 7 - 1 0 : P r o j e ct I n f o r m a t i o n w i n d o w
Tools Menu
The AdvantEdge Quick Analysis Tools menu allows the user to perform Data Analysis, display
multiple projects simultaneously using Multi-Projects Display, Overlay Plots, extract rake/relief face
data or residual stresses using Rake and Relief Face Data Extraction and Residual Stress Data
Extraction, and animate mesh force using Mesh Force Animation.
D ATA AN ALYSI S
The Data Analysis option of the AdvantEdge Quick Analysis Tools menu displays carpet plots of
simulations to easily show the relationship between feed, rake and/or speed, and temperature and
forces, helping users to view the effects of several parameters. This is especially useful when
analyzing design of experiments simulations, which create multiple simulations. To open the Data
Analysis window, select T o o l s > D a t a A n a l y si s from within the AdvantEdge Quick Analysis
window. Browse for project files to be analyzed.
N ot e : All projects to be compared must be saved in the same folder.
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Fi g u r e 1 7 - 1 1 : Se l e ct Fi l e s w i n d o w
Once all projects have been located and added to the Data Set Analysis window, the user will be
prompted to indicate the type of analysis model to be analyzed. Select T e m p e r a t u r e M o d e l
A n a l y si s.
Fi g u r e 1 7 - 1 2 : Se l e ct A n a l y si s M o d e l w i n d o w
M ULTI - PROJECTS D I SPLAY
The Multi-Projects Display option of the AdvantEdge Quick Analysis Tools menu allows up to six
contour plots or multiple force plots to be displayed at one time. To open the Multi-Projects Display
window, select T o o l s > M u l t i - P r o j e ct s D i sp l a y. A window will open, prompting the user to
select the type of plots to be compared: contour or force.
Fi g u r e 1 7 - 1 3 : Sh o w Sy st e m Se t u p w i n d o w
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Cont our Com parison
Selecting a contour comparison will open the Select Project(s) window, allowing the user to browse
for up to six contour plots to be displayed simultaneously. The user can then choose to load all
zones, the last zone, or a specific range for each project. By default, the Multi-Project Display
feature will style link each project to make analysis easier for the user (for more, see Style Linking).
Fi g u r e 1 7 - 1 4 : Se l e ct P r o j e ct ( s) w i n d o w f o r m u l t i - p r o j e ct co n t o u r co m p a r i so n
Force Plot Com parison
Selecting a force plot comparison will prompt a window to open, allowing the user to browse for the
desired force plots to display simultaneously. For 2D projects, force plots will load Fx and Fy forces,
as well as peak tool temperature. For 3D projects, force plots will load Fx, Fy, and Fz forces.
Fi g u r e 1 7 - 1 5 : Ch o o se t h e P r o j e ct s w i n d o w
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OVERLAY PLOTS
The Overlay Plots option of the AdvantEdge Quick Analysis Tools menu allows the user to view two
projects at the same time with one overlaying the other. This enables the user to easily compare
chip shapes and mesh. To use this Overlay Plots feature select T o o l s > O v e r l a y from within the
AdvantEdge Quick Analysis window. The Overlay Plot Loader window will prompt the user to select
the projects they wish to overlay. Once the projects are selected, click O K. Tecplot will load the two
projects and open the Animate Zones window (see Animation Plots). This window allows the user to
easily step through the simulation to compare the chip shape.
To help distinguish between the two projects, the mesh colors will be different.
Fi g u r e 1 7 - 1 6 : P l o t o v e r l a y o f o n e f r a m e w i t h d i f f e r e n t m e sh co l o r s
RAKE AN D RELI EF FACE D ATA EXTRACTI ON
The Rake and Relief Face Data Extraction utility of the AdvantEdge Quick Analysis Tools menu
extracts all tool boundary variables along the rake and relief face and plots them versus distance
along the rake/relief face. Simulation results must be loaded before accessing this utility. To open
the Rake and Relief Face Data Extraction Setup window, select T o o l s > R a k e a n d R e l i e f Fa ce
D a t a Ex t r a ct i o n .
Fi g u r e 1 7 - 1 7 : R a k e a n d R e l i e f Fa ce D a t a Ex t r a ct i o n Se t u p w i n d o w
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Within the Rake and Relief Face Data Extraction Setup window, select the number of simulations to
compare and browse for the appropriate simulation files (*.twb extension). Once all files have been
submitted, Tecplot will display the information requested.
Fi g u r e 1 7 - 1 8 : R a k e a n d r e l i e f f a ce d a t a e x t r a ct i o n p l o t ( t e m p e r a t u r e v s d i st a n ce a l o n g t h e
t ool)
RESI D UAL STRESS D ATA EXTRACTI ON
The Residual Stress Data Extraction utility of the AdvantEdge Quick Analysis Tools menu extracts all
data from the top of the workpiece and plots variables as a function of distance. This feature is
especially useful for Residual Stress Analysis. Simulation results must be loaded before accessing
this utility. To open the Residual Stress Data Extraction Setup window, select T o o l s > R e si d u a l
St r e ss Ex t r a ct i o n .
Fi g u r e 1 7 - 1 9 : R e si d u a l St r e ss D a t a Ex t r a ct i o n w i n d o w
Within the Residual Stress Data Extraction window, browse for the appropriate simulation file
(*.twb extension). Submit the file for extraction and a second window will open, prompting users to
select the extraction type: one line or three lines.
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Fi g u r e 1 7 - 2 0 : Ex t r a ct i o n Se t u p w i n d o w
Once all information has been submitted for the extraction, Tecplot will display the information
requested. The result will look similar to the Rake and Relief Face Data Extraction graph; however,
Tecplot will be displaying stress versus depth from the top of the workpiece.
M ESH FORCE AN I M ATI ON
The Animate Mesh-Force option of the AdvantEdge Quick Analysis Tools menu allows the user to
animate contour and time history plots at the same time, which can help during analysis. The
A n i m a t e button on the Contour Tab only allows the user to animate the contour plot.
TOOL D EFLECTI ON OUTPUT
In milling or drilling simulations, prescribed rigid body rotations are applied as boundary conditions
on the top surface of a tool. To activate the Tool Deflection output feature during the project setup
in AdvantEdge, go to Si m u l a t i o n > Si m u l a t i o n O p t i o n s > R e su l t s and select O u t p u t T o o l
D e f l e ct i o n T i m e H i st o r y. This will add three time history outputs (deflection X, deflection Y, and
deflection Z) to the simulation results file that can be viewed in Tecplot upon completion of the
simulation.
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Fi g u r e 1 7 - 2 1 : R e su l t s t a b o f Si m u l a t i o n O p t i o n s w i n d o w w i t h O u t p u t T o o l D e f l e ct i o n T i m e
H i st o r y r a d i o f e a t u r e se l e ct e d
Tool deflection outputs can be activated in Tecplot by clicking the M a p p i n g St y l e button on the
side toolbar.
Fi g u r e 1 7 - 2 2 : X , Y , a n d Z d e f l e ct i o n s f o r a d r i l l i n g si m u l a t i o n
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ANSYS Export of Steady State Data
Steady state tool data for importing into ANSYS will be created in a file named
ProjectName_steady.nst when steady state analysis is activated during the project setup in
AdvantEdge. To access the steady state analysis option, go to Si m u l a t i o n > Si m u l a t i o n
O p t i o n s > Ge n e r a l and select St e a d y St a t e A n a l y si s.
• 2D Steady State Analysis

• 3D Steady State Analysis
The created _steady.nst file will be in NASTRAN model input file format and contain steady state
data for the tool: nodal coordinates, element connectivity, mechanical/thermal boundary
conditions, nodal force, and nodal temperature. Corresponding NASTRAN model input entries are
provided below:
• Nodes
“GRID, ID, CP, X1, X2, X3”
ID Nodal ID
CP Coordinate system ID, 0 by default
X1,X2,X3 Nodal coordinates in the system CP
• Element
“CTETRA, EID, PID, G1, G2, G3, G4”
EID Element ID
PID Property ID of a PSOLID entry
G1,G2,G3,G4 Node ID
• Element property
“PSOLID, PID, MID”
PID Property ID
MID Material ID
• Material properties
“MAT1, MID, E, G, NU, RHO”
MID Material ID
E Young’s modulus
G Shear modulus
NU Poisson’s ratio
RHO Mass density
and
“MAT4, MID, K, CP, RHO”

MID Material ID
K Thermal conductivity
CP Heat capacity
RHO Density
• Nodal force loading
“FORCE, SID, G, CID, F, N1, N2, N3”
SID Load set ID
G Node ID
CID Coordinate system ID, 0 by default
F Load vector scale factor
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Re su lt s Ut ilit ie s: Te cplot | Ot h e r Te cplot Fu n ct ion a lit ie s
N1, N2, N3 Load vector components in system CID

• Nodal temperature loading
“TEMP, SID, G1, T1”
SID Temperature set ID
G1 Node ID
T1 Temperature value
• Boundary conditions
“SPC, SID, G1, C1, D1”
SID Single point constraint set
G1 Node ID
C1 Component number, up to six digits
D1 Enforced DOF value
or
“SPC1, SID, C, G1”

SID Single point constraint set
C Component number, up to six digits
G1 Node ID
17.2 — Other Tecplot Functionalities
Style Linking
Style linking is a feature within Tecplot that allows for consistent zooming, panning, and contour
levels between and within frames. This feature is very useful when using Multi-Projects Display. To
use Style Linking, follow the steps below:
1. Open Tecplot either by selecting Si m u l a t i o n > R e su l t s from within the AdvantEdge

user interface, or by choosing Tecplot from the Start Menu: St a r t > P r o g r a m s >
T h i r d W a v e Sy st e m s > A d v a n t Ed g e > T e cp l o t
2. Select T o o l s > A E M u l t i - P r o j e ct s D i sp l a y
3. When prompted, click O K to clear the existing Tecplot layout
4. Activate the Co n t o u r Co m p a r i so n radio button to view contour plots
5. From the dropdown menu, select the number of comparisons desired for multi-project
comparison
6. Click the Br o w se button, browse to the correct location, and select the appropriate file.
Repeat until all desired simulations are selected.
7. Click the O K button and Tecplot will load all the projects
8. Use the mouse to select one of the contour plots
9. Select P l o t > St y l e Li n k i n g to open the Set Links for Current Frame window
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10. In the Between Frames tab of the Set Links for Current Frame window, check all
checkboxes except for Frame Size and Positioning, as shown below:
Fi g u r e 1 7 - 2 3 : Be t w e e n Fr a m e s t a b o f Se t Li n k s f o r Cu r r e n t Fr a m e w i n d o w
11. Click A p p l y Se t t i n g t o A l l Fr a m e s, o f t h i s g r o u p
12.In the Within Frame tab, check all available checkboxes, as shown below:
Fi g u r e 1 7 - 2 4 : W i t h i n Fr a m e t a b o f Se t Li n k s f o r Cu r r e n t Fr a m e w i n d o w
13.Click A p p l y Se t t i n g t o A l l Fr a m e s
14.Click Cl o se
N ot e : Once the user has applied style linking to their Multi-Projects Display, changes
made to one project will affect all other projects. If the user zooms in on one
project, all projects will zoom in by the same amount. If the user changes the
contour levels, all the contour levels will change. This helps ensure the user makes
an apples-to-apples comparison of AdvantEdge simulations.
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Value Blanking
A user might wish to blank out some of the data in Tecplot, so only relevant data is shown. The
following steps provide one way to define a variable based off X and Y values of nodes and apply
value blanking parameters:
1. Open simulation results in Tecplot
Fi g u r e 1 7 - 2 5 : Sa m p l e si m u l a t i o n r e su l t i n T e cp l o t
2. Create an equation to define a radius variable for each node, which will calculate the
distance from the center of rotation for every node in the simulation
 Select D a t e > A l t e r > Sp e ci f y Eq u a t i o n s; the Specific Equations Window will open
Fi g u r e 1 7 - 2 6 : Sp e ci f y Eq u a t i o n s w i n d o w
 Within the Specific Equation Window, click the D a t a Se t I n f o button; the Data Set
Information window will open
 Within the Data Set Information window, verify that the variable numbers for X (mm)
and Y (mm). For this example, X (mm) and Y (mm) are 1 and 2, respectfully.
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Fi g u r e 1 7 - 2 7 : D a t a Se t I n f o r m a t i o n w i n d o w
 Click Cl o se to return to the Specify Equations window
Within the Equation(s) section of the Specify Equations window, write the following...
V24=SQRT(V1*V1+V2*V2)
...where V1 is X (mm), V2 is Y (mm) and V24 is the new variable describing the radius
Fi g u r e 1 7 - 2 8 : Sp e ci f y Eq u a t i o n s w i n d o w w i t h e q u a t i o n i n p u t
 Click the Co m p u t e button

 A message will alert the user that the data has been altered; click O K
 Click the Cl o se button to exit the Specify Equations window
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3.Select P l o t > Bl a n k i n g > V a l u e Bl a n k i n g
Fi g u r e 1 7 - 2 9 : V a l u e Bl a n k i n g w i n d o w
 Check the I n cl u d e V a l u e Bl a n k i n g checkbox

 Check the A ct i v e checkbox
 Choose V 2 4 from the Blank When dropdown menu
 Type in the desired radius to apply as a constraint. Any node within a radius (V24) value
greater than this will be hidden (blanked out).
 Click the Cl o se button
Once value blanking has been performed, the Tecplot contour will no longer show values that
should are blanked. The original Tecplot window now looks like this after applying blanking by a
radius.
Fi g u r e 1 7 - 3 0 : Sa m p l e si m u l a t i o n r e su l t i n T e cp l o t w i t h V a l u e Bl a n k i n g a p p l i e d
274
Time-History Information Export
To extract Time-History data (force components, temperature, power, etc.) from AdvantEdge
simulation results for further post-processing:
1. Open AdvantEdge simulation results in Tecplot by selecting Si m u l a t i o n > R e su l t s within the

AdvantEdge GUI
 2D Graphical User Interface (GUI)
 3D Graphical User Interface (GUI)
Fi g u r e 1 7 - 3 1 : T e cp l o t si m u l a t i o n r e su l t s w i t h A d v a n t Ed g e Q u i ck A n a l y si s w i n d o w o p e n e d
2. Open the AdvantEdge Quick Analysis window by selecting T o o l > A d v a n t Ed g e

A n a l y si s
3. Select the Time History Tab
4. Click on the time history plot to ensure it is selected, then select Fi l e > W r i t e D a t a
Fi l e
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Fi g u r e 1 7 - 3 2 : W r i t e D a t a Fi l e O p t i o n s w i n d o w
5. Select the formatting type desired. The export format shown below is an ASCll data file in
point format, which can be loaded into another program such as Microsoft Excel.
Fi g u r e 1 7 - 3 3 : Sa m p l e e x p o r t e d t i m e - h i st o r y d a t a i n A SCI I f o r m a t
276
6. Click O K
Focused Location with Model Pressure Coolant Display
The user can view the contact region for coolant pressure by manually selecting the coolant option
within the Contour & Multi–Coloring Details window. This option is only available for the 2D Focused
Coolant: Model Pressure. To access the Contour & Multi-Coloring Details window, select P l o t >
Co n t o u r / M u l t i Co l o r i n g . . . and select Co o l a n t from the pulldown list at the top of the Contour
& Multi-Coloring Details window.
Fi g u r e 1 7 - 3 4 : Co n t o u r & M u l t i - Co l o r i n g D e t a i l s w i n d o w
Fi g u r e 1 7 - 3 5 : Co o l a n t p r e ssu r e r e g i o n f o r sa m p l e w o r k p i e ce
277
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CHAPTER 18 — HPC CLIENT
The Third Wave HPC Client is an optional interface software client to Windows HPC Server 2012
designed for submitting AdvantEdge simulations to a high performance computing (HPC)
environment. The Windows HPC Server 2012 provides secure, scalable cluster resource
management, a job scheduler, and parallel processing capability.
The HPC Client can schedule or terminate a job, as well as monitor the job status within the HPC
Client GUI.
18.1 — System Requirements

• Head node: Windows Server 2012 with HPC Pack 2012
• Compute node: Windows Server 2008 R2 and Windows Server 2012
• The HPC Client will run on Windows 7 and Windows HPC Server 2008 R2
Prerequisites
To install the HPC Client:
• Installer must have administrative privileges to install the HPC Client in the target machine
• User must be a member of the HPCUsers group on the head node of the Windows HPC cluster
• Microsoft .NET Framework 4.0 client must be installed in the target machine (included in HPC
Client installer)
• Microsoft HPC Client Component must be installed in the target machine (included in HPC
Client installer)
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H PC Clie n t | I n st a lla t ion
18.2 — Installation
To install the HPC Client:
1. From the provided disc or FTP link, run HPC_Client_setup.exe on the client computer
2. Installer will prompt to install Prerequisites (first time only)
The installation will ask for a one-time HPC Client component and Microsoft .NET Framework 4.0
installation. Click I n st a l l to start the prerequisites installation.
Fi g u r e 1 8 - 1 : H P C Cl i e n t i n st a l l a t i o n p r e r e q u i si t e s
N ot e : To reduce potential compatibility problems with the TWS HPC Client interface,
choose NOT to utilize the Microsoft Update feature.
Fi g u r e 1 8 - 2 : H P C Cl i e n t I n st a l l a t i o n
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H PC Clie n t | H PC Se r ve r Se t u p
3. Once prerequisites are installed, TWS HPC Client installation will begin
N ot e : To ensure all necessary components are installed on the target machine, select a
Co m p l e t e installation.
Fi g u r e 1 8 - 3 : Co m p l e t e se t u p t y p e se l e ct e d
4. Restart the computer if prompted

5. From the disc or FTP link, install the AdvantEdgeHPCProgressServices.msi file onto the HPC
head node
6. When prompted, enter appropriate login information
7. Start the service by selecting Co n t r o l P a n e l > A d m i n i st r a t i v e T o o l > Se r v i ce s.
Right-click on the service and select St a r t .
18.3 — HPC Server Setup
License Activation Filter
For simulations to properly queue in the HPC Client cluster, a License Activation Filter must be
placed on the HPC server computer.
1. From the provided disc or FTP link, run ActivationFilter.exe on the HPC server computer.
As part of this installation, a new folder will be created and saved at
C:\ThirdWaveSystems\AdvantEdge\ActivationFilter
2. Copy the current AdvantEdge network license into this new folder and then double-click
the launch_activation.cmd file to activate the license.
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H PC Clie n t | H PC Se r ve r Se t u p
3. Open the HPC Cluster Manager on the server computer and select Opt ion s > Job
Sch e du le r Con figu r a t ion . Navigate to the Filt e r s tab
Fi g u r e 1 8 - 4 : Jo b Sch e d u l e r Co n f i g u r a t i o n W i n d o w
4. Within the Activation Filter section of the Filters tab, Br ow se to

C:\ThirdWaveSystems\AdvantEdge\ActivationFilter and select the ActivationFlexLM.exe file.
5. Click Apply to use the filter and then click OK
HPC Progress Services
For the HPC Client to accurately monitor and display job progress, HPC Progress Services must be
installed on the HPC server computer.
1. From the provided disc or FTP link, run AdvantEdgeHPCProgressServices.msi on the HPC
server computer. Progress services should now be installed, no further action is required.
License Installation
• H PC Se r ve r Com pu t e r ( H e a dn ode ) - Copy the license file thirdwave.lic to the location

C:\ThirdWaveSystems\AdvantEdge\TWSLicense and start license service by running
InstallLicenseServices.exe in the same folder.
• Com pu t e N ode s – On each compute node, copy the same license file thirdwave.lic to the
location C:\ThirdWaveSystems\AdvantEdge\TWSLicense
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H PC Clie n t | H PC Clie n t GUI
• Clie n t Com pu t e r – On each client computer, copy the same license file thirdwave.lic to the
location C:\ThirdWaveSystems\AdvantEdge\TWSLicense
N ot e : Above mentioned license files should always be named thirdwave.lic
18.4 — HPC Client GUI

The HPC Client GUI allows users to set up account information, view relevant simulation data, and
submit simulations. Relevant simulation data can be accessed within the Job Queue, Job Task, and
Job Progress tabs located below the account information icons.
To open the TWS HPC Client, select St a r t > A l l P r o g r a m s > T h i r d W a v e Sy st e m s

A d v a n t Ed g e > T W S H P C Cl i e n t .
Fi g u r e 1 8 - 5 : T W S H P C Cl i e n t GU I
User Credentials
The HPC Client utilizes Windows network account information to manage users who are logging in
and utilizing the HPC system. Therefore, the first time a user logs into the system (or any time user
information changes), credentials must be established in the software. To set up user credentials,
click the U se r Cr e d e n t i a l s icon ( ) at the upper left of the HPC Client GUI. Within the User
Credentials window, enter a new user, input the necessary information and click O K. To delete old
user names and passwords, click Cl e a r Ca ch e .
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Application Configuration
Before using the TWS HPC Client, users must define settings for various keywords and commands
used to identify the cluster and correctly submit AdvantEdge simulations within the HPC Client GUI.
To define application settings, click the A p p l i ca t i o n Co n f i g u r a t i o n icon ( ).
Fi g u r e 1 8 - 6 : U se r Cr e d e n t i a l s W i n d o w
Fi g u r e 1 8 - 7 : A p p l i ca t i o n Se t t i n g s W i n d o w
Descriptions of application keywords and commands are as follows:
• H P CW o r k P a t h — data storage location for the compute nodes. This must be a shared drive
with a UNC path format (for example: \\headnode\users\).
• H P CCl u st e r N a m e — head/server node host name
• T W SCl u st e r N o d e — cluster node group where the simulation will be sent for computing.
The administrator can segregate the cluster for different groups.
• H P CCo m m a n d Li n e 2 D — command for executing AdvantEdge 2D simulations. start /low /
b /wait advanteng.exe –p2, for example, tells the cluster to use low priority, not create a new
window, wait until the task is done, what the engine is called, and to use 2-core parallel.
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• H P CCo m m a n d Li n e 3 D — command for executing AdvantEdge 3D simulations. Setup is the

same as 2D, but refers to the 3D engine instead.
• H P CA p p r o v e P a t h — path for temporary data storage after job is done running on the
cluster, which frees up space on the cluster. Data can be kept at this location permanently, or
moved from here to a storage database.
• M o v e T o A p p r o v e Cm d — command to transfer data from the cluster to a temporary
location to free up space on the cluster
• H P CJo b Fo l d e r N a m i n g — what the job folder should be named upon submission of a new
case (see Submitting Jobs to the HPC Client). It will either use the folder of the submitted
case or the project/job name of the submitted case. This variable can be set to ID_FOLDERNAME
or ID_FILENAME to use either the folder name or project name, respectively.
• T W SSa v e Jo b Co m m a n d Fi l e — path to the file that contains the command to copy
simulation data from the temporary location to a storage database location. This command
file will be executed when the user right-clicks on the job listing in the Job Queue tab and
selects Se n d Jo b R e su l t t o D a t a b a se .
• H P CLi ce n se A ct i v a t i o n — checks for the License Activation Filter on the HPC server. This
will queue the simulation on the cluster until a license becomes available. By default, this is
set to ON. If it is turned OFF, the HPC server will not check for license availability and the job
progress will not be updated.
• Li ce n se T y p e — Lets the user choose between execution-counted and core-counted
licensing. Enter EXECUTION_COUNTED or CORE_COUNTED in the field setting to activate
applicable licensing scheme (See Application Settings Window)
• H P CFi l e Co p y Fr o m X M L — submits only the required setup files to the cluster from the
project folder
• H P CJo b T e m p l a t e — specifies the job template the simulation will run against
Email Notification
If desired, the TWS HPC Client can notify the user about the status of a simulation through email
notifications. To activate this feature, click the Em a i l N o t i f i ca t i o n icon ( ) at the upper left of
the HPC Client GUI.
Fi g u r e 1 8 - 8 : Em a i l N o t i f i ca t i o n w i n d o w
285
Within the Email Notification window, users can choose to receive email notifications when jobs
start or are completed, or both. The HPC Client email will contain job details such as Job ID, project
name, and simulation status.
Job Tracking
The job tabs of the HPC Client GUI allow the user to track jobs currently in the Job Queue, whether
an additional Job Task has been run for a selected job, and the current detailed Job Progress of
each task. This is the main area for tracking current and past simulations within the TWS HPC
Client.
Job Queue
The Job Queue tab of the HPC Client GUI shows the current list of simulations that are waiting to be
submitted; currently running; and recently finished, failed, or cancelled. It will also show the
simulations that have been transferred to a temporary storage location. Users can browse to this
location by right-clicking on the desired job and selecting Ex p l o r e t o W o r k D i r e ct o r y.
Fi g u r e 1 8 - 9 : Jo b Q u e u e t a b o f T W S H P C Cl i e n t
This list of tasks provides a quick overview of recent simulation activities, as populated by the HPC
Client. An explanation of Job Queue column contents is provided below:
• St a t e — graphical representation of current progress status
— job is currently in progress
— job has finished running
286
— job submission failed or cancelled through Microsoft HPC Job Manager
N ot e : If the user cancels a submission job from the HPC Client there will be no icon in the
state field, but the status will show as User Cancelled.
— job has failed
— job is waiting to be submitted
• Jo b I d — unique number assigned to each task as it is submitted to the HPC Client

• Jo b N a m e — project/job name from AdvantEdge for each task (for example, <Job Name>.inp)
• St a t u s — current status of each task, as displayed graphically in the State column
(explained above)
• O w n e r — user name/login name for each task
• P r i o r i t y — task priority as set in the Application Configuration window. Determines how the
processor will prioritize this task relative to other programs currently running.
• P r o g r e ss % — current percentage completion of the task based on the current and total
length of cut for the simulation
• Su b m i t T i m e — time the task was initially submitted
• R e q u e st e d R e so u r ce — computing resources requested to run the task
• Er r o r M e ssa g e — details on a task that has failed or been canceled
• P e n d i n g R e a so n — status of a queued job (for example, not enough available core
indicates the queue is currently full)
Job Task
The Job Task tab of the HPC Client GUI allows users to view the specific processes that are planned
to run for a highlighted task, which is selected from either the Job Queue or Job Progress tabs. The
TWS HPC Client will show two processes for the selected task: the first process (Task ID#1) will run
the simulation on the HPC cluster, the second process (TaskID#2) will copy the completed simulation
to a secondary, permanent storage location.
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Fi g u r e 1 8 - 1 0 : Jo b T a sk t a b o f T W S H P C Cl i e n t
An explanation of Job Task column contents is provided below:
• T a sk I d — order of operations for the original task

• N a m e — type of action taken on the original task
• Co m m a n d Li n e — commands run for this action on the original task
• St a r t T i m e — time when the task began to run
• En d T i m e — time when the task stopped running
• O u t p u t — output for each action taken
• Er r o r M e ssa g e — details on a task that has failed or been canceled
• P a r e n t Jo b I d — job ID of the original task
• St a t e — task status (finished, running, failed, cancelled, queued)
• M a x i m u m N u m b e r O f Co r e s — maximum number of cores the task is allowed to use
• M i n i m u m N u m b e r O f Co r e s — minimum number of cores the task is allowed to use
• W o r k D i r e ct o r y — task directory
Job Progress
The Job Progress tab of the HPC Client GUI lists all simulations stored in the HPCWorkPath that are
associated with the user. The job progress tab does not show simulation jobs that have been
transferred from the HPCWorkPath location to the temporary storage location; these are listed only
on the Job Queue tab. The Job Progress tab also shows additional status details for tasks, including
the current length of cut, total length of cut, and the directory in which the simulation is stored.
This information is populated by a *.csv file written from the AdvantEdge engine.
288
Fi g u r e 1 8 - 1 1 : Jo b P r o g r e ss t a b o f T W S H P C Cl i e n t
An explanation of Job Progress column contents is provided below:
• St a t e — graphical representation of current progress status
— job is currently in progress
— job has finished running
— job submission failed or cancelled through Microsoft HPC Job Manager
N ot e : If the user cancels a submission job from the HPC Client there will be no icon in the
state field, but the status will show as User Cancelled.
— job has failed
— job is waiting to be submitted
• Jo b N a m e — project/job name from AdvantEdge for each task (for example, <Job Name>.inp)
• Su b m i t T i m e — time the task started running on the HPC cluster
• La st M o d i f i e d — last time the simulation wrote to the *.csv progress file
• Cu r r e n t Cu t — current length of cut for the simulation
• T o t a l Cu t — total length of cut set for the simulation
• St a t u s — current status of each task, as displayed graphically in the State column
(explained above)
• Est im a t e d Tim e t o Com ple t ion — The approximate simulation time is estimated using the
current length of cut and the elapsed time since the simulation started. This time will change
289
H PC Clie n t | Su bm it t in g Jobs t o t h e H PC Clie n t
as the simulation progresses and will become more accurate as the simulation reaches a
stable number of workpiece elements.
• P r o g r e ss % — current percentage completion of the task based on the current and total
length of cut for the simulation
• W o r k D i r e ct o r y — task directory
18.5 — Submitting Jobs to the HPC Client
Using the AdvantEdge GUI
The desired method for submitting jobs to the HPC Client is through the AdvantEdge GUI. Using this
method, job attributes are stored in a metadata (XML) file, which users access through the
AdvantEdge GUI. This file can be used as a tag to the project folder by a database system. By
default, a copy is placed in each project setup folder.

CREATI N G AN XM L FI LE
Before submitting any job to the HPC Client, a metadata file must first be created using XML editing
software. This XML file may be used for an unlimited number of projects over time, but cannot be
modified after creation. XML files may be generated from a metadata template located at
C:\ThirdWaveSystems\AdvantEdge\Data\XML\AdvantEdge_Input_Template.xsd.
1. Open the metadata template file (XSD) using an XML editor

2. Revise the XSD file as desired
3. Generate an XML file from the XSD file using the XML editor
The sample code and schema of the metadata, as well as the resulting XML, are provided below:
Sam ple code of t he default XML file
<HPCJobData>
<HPCJobAttribute Mandatory=”true”>
<DisplayName>Project Name</DisplayName>
<ItemSequence>0</ItemSequence>
<ItemType>
<Choice>false</Choice>
</ItemType>
<ItemValue>Proj_1</ItemValue>
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</HPCJobAttribute>
<DisplayName>Job Category</DisplayName>
<ItemType>
<Choice>false</Choice>
</ItemType>
<ItemValue>Turning</ItemValue>
<ItemValue>Milling</ItemValue>
<ItemValue>Drilling</ItemValue>
</HPCJobAttribute>
<HPCJobAttribute Mandatory=”false”>
<DisplayName>Parallel Processing</DisplayName>
<ItemType>
<Boolean>true</Boolean>
</ItemType>
<ItemValue>Yes</ItemValue>
</HPCJobAttribute>
<DisplayName>Workpiece Material</DisplayName>
<ItemType>
<String>true</String>
</ItemType>
<ItemValue>Enter Text</ItemValue>
</HPCJobAttribute>
<DisplayName>Tool Material</DisplayName>
<ItemType>
<String>true</String>
</ItemType>
<ItemValue>Enter text</ItemValue>
</HPCJobAttribute>
<DisplayName>Number of Cores</DisplayName>
<ItemType>
<Integer>true</Integer>
</ItemType>
<ItemValue>2</ItemValue>
</HPCJobAttribute>
</HPCJobData>
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Fi g u r e 1 8 - 1 2 : Sch e m a o f d e f a u l t X M L f i l e
STAN D ARD AD VAN TED GE SUBM I SSI ON ( 2 D AN D 3 D )
1. Set up a simulation in AdvantEdge

 2D Getting Started
 3D Getting Started
2. Select P r e f e r e n ce s > Se t P r e f e r e n ce s
3. Within the Metadata tab of the Set Preferences window, Br o w se to the desired XML file
N ot e : If not specified, AdvantEdge will automatically default to the most recently-used

XML file.
4. Select Si m u l a t i o n > H P C Jo b Cl a ssi f i ca t i o n . The HPC Job Classification window will

open to display up to 50 attributes of the selected metadata file.
Fi g u r e 1 8 - 1 3 : H P C Jo b Cl a ssi f i ca t i o n w i n d o w
292
5. Enter all job classification values and click O K. Sa v e the simulation in a new folder (see
Flexible Licensing is an upgrade available for AdvantEdge. It provides the user more
flexibility by breaking the license up by core count instead of execution. With this
capability users are able to get greater through-put in order to quickly solve problems.
For more information or to purchase this upgrade, contact sales@thirdwavesys.com.).
N ot e : If the project is erroneously saved in a folder containing other simulation setups, all
files will be copied to the cluster.
6. Select Si m u l a t i o n > Su b m i t > Su b m i t H P C Jo b . The Submit HPC Simulation

window will open.
Fi g u r e 1 8 - 1 4 : Su b m i t Si m u l a t i o n w i n d o w
7. Indicate whether the job is new or a restart, then click O K. The HPC Client will open,
showing the submitted job in the Job Queue where its status can be tracked.
PARAM ETRI C STUD Y I N TERFACE SUBM I SSI ON ( 2 D ON LY)
1. Set up a simulation in AdvantEdge (see 2D Getting Started)

2. Select D e si g n > P a r a m e t r i c St u d y I n t e r f a ce . The Parametric Study Interface
window will open.
293
Fi g u r e 1 8 - 1 5 : P a r a m e t r i c St u d y I n t e r f a ce w i n d o w
3. Within the Parametric Study Interface window, set up the appropriate cutting conditions
(see 2D Parametric Study)
4. Click the H P C Su b m i ssi o n button at the bottom of the Parametric Study Interface
window. The HPC Client will open, showing the submitted job in the Job Queue where its
status can be tracked.
Using the HPC Client GUI
To open the TWS HPC Client software, select St a r t > A l l P r o g r a m s > T h i r d W a v e Sy st e m s

A d v a n t Ed g e > T W S H P C Cl i e n t .
Users may submit simulations to the HPC Client using the HPC Client GUI only after User
Credentials and Application Configuration settings have been defined. Tasks will be added to the Job
Queue and begin running as space becomes available on the HPC cluster.
Users can perform a variety of actions within the HPC Client GUI such as exploring the work
directory, viewing results, showing job tasks, and updating job progress by simply right-clicking on
the simulation within the HPC Client.
SUBM I T
Using the HPC Client GUI, users can submit single and multiple jobs along with a folder tag and
number of cores setting by clicking the Su b m i t button. The Submit Job window will open, allowing
users to specify number of cores to be used, as well as the executable and simulation sources.
294
Fi g u r e 1 8 - 1 6 : Su b m i t Jo b w i n d o w
Execut able Source
The executable source to run the simulation may be identified by one of three settings:
• A p p l i ca t i o n Se t t i n g — uses executable inputs taken from the HPC Client Application

Configuration
• D e f a u l t o n Co m p u t e N o d e — uses executable inputs installed on the compute node
• Se l e ct Fo l d e r — uses executable inputs from a folder stored at some other location
Sim ulat ion Source
If Multiple Submissions is selected as the simulation source, the user must browse to the location of
a parent folder. Within this folder, the user must have already saved each project in a unique own
folder, along with required setup files. HPC Client will copy all folders inside this parent folder and
run them using the executable source identified.
An optional tag can be appended to the new parent folder (created by the HPC Client), as well as all
project folders within. For a single submission, this tag will be on the added to the folder name.
REFRESH
Clicking the R e f r e sh button will update the job progress of the active HPC Client tab (either Job
Queue or Job Progress). If there are large number of simulations in the HPC Client, this refresh may
take few minutes to complete.
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CHAPTER 19 — REFERENCES
19.1 — Rake Angle Guide
297
Re fe r e n ce s | I SO St a n da r d Tool D e sign a t ion s
19.2 — ISO Standard Tool Designations
19.3 — AdvantEdge Mesh Error Code List
Ta ble 1 9 .1 : Adva n t Edge M e sh Er r or Code List
ID D e scr ipt ion Re com m e n da t ion
1001 Error, Command not understood Use GUI to mesh simulation
1002 Error, Unsupported tool process Use GUI to set up simulation
1003 Imported wp require indexable

tools to be tool assembly or solid
tool
1020 Error writing to STP file
298
Re fe r e n ce s | Adva n t Edge M e sh Er r or Code List
1021 Internal error Contact Third Wave Support
1025 For workpiece STEP import, the

tool must be STEP import too
1030 Error due to system memory Reduce tool resolution and/or tool
shortage dimensions
1031 File access error
1040 Error due to system memory Reduce tool resolution and/or tool
shortage dimensions
1060 Error, Unsupported tool process Use GUI to set up simulation
1090 STEP import is not supported
1100 Error, NASTRAN import tool is

supported for turning only
2001 Error, Tool radius is too small Check insert size and tool radius
2002 Error, Workpiece height is larger Check workpiece height and tool
than tool height height
2003 Error, The axial depth of cut is Check axial depth of cut and tool
larger than the tool height height
2004 Error, feed should be less than

50% of the tool height
2005 Error, Axial depth of cut is larger Check axial depth of cut and tool
than the tool height height
2006 Flutes are too close
2010 Error, Tool core diameter is Check tool core diameter and tool
larger than tool cutter diameter cutter diameter
2011 Error, Radial relief angle is tool Reduce radial relief angle to less
large (>90 degrees) than 90 degrees
2012 Error, Number of flutes is less Increase number of flutes

than 2
2013 Error in creating the tool Check tool diameter, core

diameter, rake angle
2020 Error, Wrong parameter type Choose parameter type from GUI
2030 Error, Input depth of cut exceeds Check depth of cut and tool height
the tool height
2040 Error in corner radius, it must be Increase nose radius to non-zero

greater than zero number
2041 Error, Mesh is too fine on the Check tool tip radius, reduce
cutting radius number of facets to less than 30
2042 Error, Cutter diameter should be Check cutter diameter and insert
between 2 and 36 times of the width
inscribed diameter
299
2050 Error in nose radius, it must be Increase nose radius to non-zero

greater than zero number
2052 Error, Custom tool requires 4 Add points to custom tool

tool points in geometry geometry
description
2071 Error, Radial relief angle Reduce radial relief angle to less
than 90 degrees

than 2
2073 Error, The tool width of land Increase tool width of land to non-
must be greater than zero zero number
2080 Error, Tool process is not Use GUI to set up simulation

supported
2091 Tool is too short for 5 axis milling
2110 Error, Tool core diameter is Check tool diameter and tool
2111 Error, Radial relief angle is too Reduce radial relief angle to less
large (>90 degrees) than 90 degrees

than 2
2122 Error, number of flutes is less Increase number of flutes

than 2
2130 Error, wrong input parameter for

square tool
2131 Error in generating the tool Check inputs
2200 Tool deflection beam length has Change beam length or deselect
been zero tool deflection
2210 Initial starting depth is too large
300
2211 Feed is too large, or tool height

is too small
2212 Failed to create workpiece layers Check layer thickness, starting

depths, etc.
2213 Workpiece layer thickness is too Change input

small
2214 Oblique drilling angles are too

large, max 45 degrees
2215 Error in detecting tool profile
2220 Drill parameters are not

appropriate
2221 Wrong input parameters for split

point drill
2250 Workpiece diameter is smaller

than the minimum value
2251 Depth of cut is smaller than the

minimum value
2252 Depth of cut exceeds the tool

size
2253 Initial radial position is too close Change initial radial position to at
to the center least two times the feed
2254 Offset is larger than 80% of the

starting radius
2270 Starting depth is larger than the

tool height
2271 Pilot hole diameter or depth is

too small. The minimum value is
01 mm
2272 Pilot hole diameter is larger than

the workpiece size
2273 Failed to create pilot hole
2301 Tool width is less than the depth

of cut
2302 Workpiece diameter is too small
2303 Depth of cut is more than 90%

of workpiece radius
2310 Workpiece cutter diameter is too

small
2311 Too many teeth, maximum 6 for

boring
2312 Tool is too big, or workpiece

inner diameter is too small
2313 Error in tool profile
301
2314 Starting depth is larger than

workpiece height
2315 Side rake angle of tool is equal

to or larger than relief angle
3001 Error in generating tool volume Check geometry, surface mesh,

mesh and meshing parameters
3002 Error occurred while reading the

STEP file
3003 Memory allocation failed during

volume meshing
3004 Volume meshing failed
3005 Volume meshing failed
3010 Error in generating workpiece Check geometry, surface mesh,

volume mesh and meshing parameters
3018 Internal meshing error Check input parameters or contact

Third Wave Support
3019 Error in generating workpiece Check process parameters and

surface mesh tool geometry
3020 Error in generating tool surface Contact Third Wave Support

mesh
3021 Error in surface mesh Check geometry and meshing

parameters
3025 Error in generating tool surface Check STL file and resolution
mesh from the STL file
4001 Failed to create drill Check input parameters
5001 Error in generating workpiece Contact Third Wave Support

5120 Tool width is less than workpiece

width
5150 Error in generating workpiece;

the insert shape/geometry may
be wrong
5200 Error in generating workpiece Check tool geometry and position
6001 Error in positioning the tool and For imported tools, check initial
workpiece position
workpiece position
workpiece position
workpiece position
302
Re fe r e n ce s | Com m on Type s of Ba d Ge om e t r y for STEP I m por t s
6050 Error in generating the cutting Check process parameters

tool
workpiece position
6070 Nose tool boundary condition is

not complete defined
9001 Error in generating the geometry Contact Third Wave Support
9007 Error in surface mesh Contact Third Wave Support
9008 Error in edge curvature Contact Third Wave Support
9009 Error in generating drill Check input tool geometry

parameters
9010 Error in operating mesh Contact Third Wave Support
9999 Internal error Contact Third Wave Support
10001 DXF import Cannot open input file
10002 DXF import User-defined coordinate system

not supported
10003 DXF import Profile is not on an XY plane

10004 DXF import There are no valid entries in the
file to form a closed profile
10005 DXF import Tool profile is not closed
10006 DXF import Verify DXF imported profile
19.4 — Common Types of Bad Geometry for STEP

Imports
Spot/Tiny Faces
• Sy m p t o m : Extremely tiny surface area
303
• Co n se q u e n ce : Meshing errors
• R e m e d y : Re-open the model in the native CAD system and eliminate small features
inconsequential for simulation. Avoid using hybrid modeling techniques that may generate
small trimmed faces.
Fi g u r e 1 9 - 1 : Ex a m p l e o f sp o t f a ce s
Zero Volume
• Sy m p t o m : A volume with faces that do not form a closed shell or a set of shells without an
enclosing volume. Might occur when exporting the solid model from a loose tolerance system
or when the exporting tolerance for the STEP file was not set to a tight value.
• Co n se q u e n ce : Gaps between surfaces may be so large that AdvantEdge cannot
reconstruct the solid volume meaningfully without significantly distorting the geometry.
Possible aborted meshing.
• R e m e d y : Proceed to meshing; however, often reasonable mesh may not have been
generated successfully. In cases of aborted meshing, AdvantEdge will indicate problematic
faces. Always check final mesh and edge preparation before proceeding to simulation.
Multiple Volumes
• Sy m p t o m : Multiple volumes exported to the STEP file

• Co n se q u e n ce : File will not mesh (multiple volumes not supported by AdvantEdge)
• R e m e d y : Export only the primary cutting tool. For indexable tools, export a single insert for
geometry and specify the number of inserts in the 3D Graphical User Interface (GUI) for the
corresponding process.
304
Edges with Zero Length
• Sy m p t o m : Sets of duplicate vertices, or vertices extremely close to each other, produce tiny
edges or edges with zero length. Might occur when exporting the solid model from a loose
tolerance system or when the exporting tolerance for the STEP file was not set to a tight
value.
• Co n se q u e n ce : Gaps between surfaces may be so large that AdvantEdge cannot
reconstruct the solid volume meaningfully without significantly distorting the geometry. Solid
not created out of surface definitions provided in the STEP file; possible aborted meshing.
• R e m e d y : Proceed to meshing. In cases of aborted meshing, AdvantEdge will indicate
problematic faces. Always check final mesh and edge preparation before proceeding to
simulation.
Fi g u r e 1 9 - 2 : Ex a m p l e o f e d g e s w i t h z e r o l e n g t h ; p r o b l e m e d g e s h i g h l i g h t e d
Twisted Faces
• Sy m p t o m : Faces that are twisted or folded back on themselves due to reversed order of
vertices or edges, leading to incorrect normals.
• Co n se q u e n ce : Generally not a problem with meshing. Still, 3D model may look inaccurate
due to bad shading.
• R e m e d y : No treatment necessary. However, problem may suggest bad translation of
geometry in other places. Visually inspect the model before proceeding.
305
Re fe r e n ce s | STEP File Ca se St u die s a n d Tr ou ble sh oot in g
Fi g u r e 1 9 - 3 : Ex a m p l e o f t w i st e d f a ce s; m o d e l s w i t h b a d sh a d i n g so m e t i m e s e x h i b i t
p r o b l e m s w h i l e m e sh i n g
19.5 — STEP File Case Studies and Troubleshooting
Suspicious Geometry Causes Bad Visualization
• Sy m p t o m : Overall geometry seems flawless, but upon closer inspection, visualization near
highlighted the surfaces appears to be incorrect
• Co n se q u e n ce : Tool mesh generation failure, despite attempts to heal the file
• R e m e d y : Re-export files from a CAD system with tighter Tolerances. Most commercial CAD
systems automatically attempt to correct loaded STEP files if the corrections do not
significantly modify the geometry. Hence, simply opening and saving the CAD may correct
the problems and make the STEP file suitable for AdvantEdge simulation. In the example
provided below, the original geometry was generated in Unigraphics CAD system, corrected
in CATIA, and re-opened in AdvantEdge with the STEP file healing feature turned on (see
Healing Imported STEP Files).
Fi g u r e 1 9 - 4 : Su sp i ci o u s g e o m e t r y d e t e ct i o n e x a m p l e
306
Free Entities
• Sy m p t o m : Free entities observed in STEP files

• Co n se q u e n ce : Check Geometry feature detects and displays free entities in red, indicating
that they are not part of any surface or solid. Mesh generation failure.
• R e m e d y : Delete extra entities in CAD system and re-export STEP files. In the example
provided below, extra entities were deleted using CATIA and re-imported into AdvantEdge;
no additional problems were immediately observed.
Fi g u r e 1 9 - 5 : Fr e e e n t i t i e s d e t e ct i o n e x a m p l e
STEP File Could Not be Opened
• P o ssi b l e Fa ct o r s:
(1) incorrect STEP format
(2) presence of special characters or Unicode text
(3) reference to non-existent geometry
(4) problematic entities in STEP file
• Sy m p t o m : STEP file error notice
• Co n se q u e n ce : STEP File Import aborted
• R e m e d y : To check for the presence of special characters, the STEP file can be opened in a
text editor such as Microsoft Wordpad or Notepad. Special characters may be present in the
first few lines of the STEP file (file name, assembly name, author, etc.). The STEP file can also
be opened in a commercial CAD system and examined for errors. If the STEP file cannot be
opened in the CAD system, the file may be corrupt.
In the example provided below, the STEP file was found to contain untrimmed surfaces. The
remaining geometry was examined for additional problems by hiding the suspicious untrimmed
faces and creating two new faces in their place – using the Fi l l Su r f a ce option – to form a closed
solid volume. With the addition of the two new faces, a closed shell was formed. The completed
solid volume was then exported.
307
Fi g u r e 1 9 - 6 : U n t r i m m e d f a ce s d e t e ct i o n
N ot e : Highlighting the required entities will prevent other entities from being exported
into the STEP file. In the example provided here, the faces forming a closed volume
were exported by disregarding the untrimmed faces. Alternatively, these faces
could also have been deleted from the file, leaving the remaining faces to be
exported to the STEP file. The exported faces form a closed volume in AdvantEdge,
allowing the file to be meshed.
308
Fi g u r e 1 9 - 7 : U n t r i m m e d f a ce s h i d d e n f r o m v i e w
Fi g u r e 1 9 - 8 : M i ssi n g f a ce s g e n e r a t e d u si n g CA T I A Fi l l Su r f a ce f e a t u r e
Face Could Not Be Meshed
• Sy m p t o m : Dark shading indicated problems with surface definition

• Co n se q u e n ce : Mesh generation failure
309
• R e m e d y : Open file in a commercial CAD package and re-export. In the example provided
below, CATIA was used to re-export the file. Reopening the file showed additional problems
with shading, as well as zero edge lengths. The re-imported STEP file then meshed
successfully with the healing feature turned on.
Fi g u r e 1 9 - 9 : P r o b l e m a t i c f a ce d e t e ct e d
Fi g u r e 1 9 - 1 0 : A d d i t i o n a l p r o b l e m s d e t e ct e d
Fi g u r e 1 9 - 1 1 : P r o b l e m a t i c f a ce i n d i ca t e d
310
Fi g u r e 1 9 - 1 2 : M e sh e d w i t h H e a l i n g f e a t u r e se l e ct e d
Fi g u r e 1 9 - 1 3 : Fr e e v e r t e x i n si d e t o o l v o l u m e l o ca t e d
Fi g u r e 1 9 - 1 4 : M e sh e d w i t h f r e e e n t i t i e s d e t e ct e d
General STEP File Manipulation & Export in CATIA
Although the following example shows steps specific to CATIA, similar features can often be found
in other commercial CAD systems.
• Co n se q u e n ce : Mesh generation failure in a spherical surface near the cutting edge of the
tool
• R e m e d y : To correct the problems the following steps were undertaken:
1. Tolerances for geometry creation and STEP export were set in CATIA.
311
2. Solid object was decomposed into constituent surfaces

3. “Bad” faces were deleted from the CAD file
4. New surface was created using the Fill Surface feature. Resultant surface did not satisfy
the design intent, generating a surface with an equation inconsistent with original design
intent
5. Surfaces generated by Fill Surface feature were deleted and new ones created using the
Blended Surface feature
6. Blended Surface feature generated a surface between two curves (“support surface”) by
maintaining the continuity of the surfaces to which the edges belonged
A visual step-by-step of this remedy is provided below:
Fi g u r e 1 9 - 1 5 : P r o b l e m a t i c su r f a ce e n co u n t e r e d
Fi g u r e 1 9 - 1 6 : ST EP f i l e e x p o r t o p t i o n s f r o m CA T I A T o o l > O p t i o n s m e n u
312
Fi g u r e 1 9 - 1 7 : T o l e r a n ce se t t i n g o p t i o n s f o r CA T I A st e p f i l e e x p o r t
Fi g u r e 1 9 - 1 8 : Se l e ct so l i d o b j e ct f r o m t o p o l o g y t r e e , cl i ck t h e D i sa sse m b l e b u t t o n t o o b t a i n
d e co m p o si t i o n i n t o t h e u n d e r l y i n g su r f a ce s
313
Fi g u r e 1 9 - 1 9 : D i sa sse m b l e su r f a ce f o r t h e o b j e ct , se l e ct so l i d o b j e ct f r o m t o p o l o g y t r e e a n d
de le t e
Fi g u r e 1 9 - 2 0 : M a n i p u l a t e “ b a d ” su r f a ce s, d e l e t e t h i n su r f a ce s o r su r f a ce s w i t h i n co n si st e n t
n or m a ls
314
Fi g u r e 1 9 - 2 1 : M a n i p u l a t e su r f a ce s, a d d n e w su r f a ce s b y f i l l i n g t h e a r e a b e t w e e n a se t o f
cl o se d e d g e s
Fi g u r e 1 9 - 2 2 : M a n i p u l a t e su r f a ce s, a d d n e w su r f a ce s b y f i l l i n g t h e a r e a b e t w e e n a se t o f
cl o se d e d g e s
315
Fi g u r e 1 9 - 2 3 : Fi l l i n g t h e su r f a ce d o e s n o t f u l f i l t h e d e si g n i n t e n t ; u n a cce p t a b l e e d g e
pr e pa r a t ion
Fi g u r e 1 9 - 2 4 : D e l e t e t h e su r f a ce
316
Fi g u r e 1 9 - 2 5 : Sp e ci f y b l e n d i n g cu r v e s a n d su p p o r t su r f a ce s
Fi g u r e 1 9 - 2 6 : Sp e ci f y b l e n d i n g cu r v e s a n d su p p o r t su r f a ce s
317
Fi g u r e 1 9 - 2 7 : Bl e n d e d su r f a ce a n d a sso ci a t e d w a r n i n g f r o m CA T I A
VOLUM E M ESH I N G ERRORS
Typically, volume meshing errors are caused by overlapping surface meshes due to either the
presence of multiple volumes or edges with zero length. These problems must be addressed before
importing STEP files into AdvantEdge. In cases where the reasons for volume meshing failure are
not obvious, success may be achieved by changing the minimum edge length parameter. Surface
mesh edges smaller than this parameter will be collapsed during volume meshing. Using a value
close to 10 microns will eliminate small edges and ultimately result in successful meshing and
simulation.
N ot e : The minimum edge length value should never exceed 40 microns, as this may col-
lapse too many edges and lead to unrealistic tool mesh.
Additional Resources
Several online documents provide useful information regarding geometry checking and exporting
STEP files from different CAD systems. AdvantEdge users may find some of this information to be
especially useful when faced with meshing failure: http://www.cax-if.org/
joint_testing_info.html#recpracs.
318
Re fe r e n ce s | W e a r M ode ls: Est im a t in g M a t e r ia l Con st a n t s Ba se d On Ex pe r im e n t a l D a t a
19.6 — Wear Models: Estimating Material Constants

Based On Experimental Data
Experimental cutting data can be used to derive K and  values for the Tool Wear model feature in
AdvantEdge. The custom wear model in AdvantEdge is calculated using the equation below:

w· = K  e  – --------------------------  V
 T + 273.15
Wear is measured by w· , the volume loss per unit area per unit time (a wear rate). K and  are
wear model constants. These can be derived from experimental data and AdvantEdge simulations.
An example of experimental data used to find K and  would be flank wear lengths at various
times for given cutting conditions. T represents the steady state temperature of a tool with a given
amount of wear.
N ot e : All values used in this example are arbitrary and should not be taken as a recom-
mendation for cutting conditions to be run. A proposed process for determining K ,
 , and T is summarized as follows:
Ta ble 1 9 .2 : Sa m ple Cu t t in g Con dit ion s for D e t e r m in in g K ,  , a n d T
Cu t t in g Con dit ion Fe e d Spe e d
A 0.05 200
B 0.25 400
7. Acquire flank wear measurements at several times over several cutting conditions
8. Determine tool wear in the X and Y directions. This is done using flank wear (X-direction)
and the tool geometry at discrete time intervals where experimental data was collected.
The wear rates are important factors in finding optimal K and  values.
Fi g u r e 1 9 - 2 8 : Fl a n k w e a r i n X d i r e ct i o n ( r e d ) a n d Y d i r e ct i o n ( b l u e )
9. After determining X and Y wear rates, identify a few key points for each case to collect
temperature data
319
Re fe r e n ce s | Te m pe r a t u r e D e pe n de n t Con st it u t ive M ode ls: Re la t in g Con du ct ivit y t o H e a t
Tr a n sfe r
10. Collect temperature data for specific cutting conditions. One possible way would be to run
AdvantEdge simulations with custom tools with equivalent flank wear, such as shown
below.
Fi g u r e 1 9 - 2 9 : Cu st o m t o o l sh o w i n g f l a n k w e a r
11. Substitute this temperature into the wear equation, using an estimated K and  . The
default K and  are good starting points.
Ta ble 1 9 .3 : Se le ct e d Ex pe r im e n t a l Ca se s w it h Est im a t e d W e a r
Sa m ple Spe e d Fe e d Te m p K  w· w· Ex pe r im .
A-1 200 0.05 700 100E-04 3000 calculated calculated
A-10 200 0.05 850 100E-04 3000 calculated calculated
B-0.5 400 0.25 900 100E-04 3000 calculated calculated
B-2 400 0.25 1000 100E-04 3000 calculated calculated
12. Using iterative solving methods, optimize K and  to minimize the difference between
predicted and experimental values
N ot e : Both K and  will be positive values.
19.7 — Temperature Dependent Constitutive Models:

Relating Conductivity to Heat Transfer
The figure below shows the Heat Transfer tab within the Workpiece Material window. The first box
within this tab displays the baseline thermal conductivity (k). For this example, the baseline
thermal conductivity equals 100 W/m°C.
320
Tr a n sfe r
Fi g u r e 1 9 - 3 0 : H e a t T r a n sf e r t a b o f W o r k p i e ce M a t e r i a l w i n d o w
In the figure below, the Conductivity tab within the Workpiece Material window is shown. This tab is
only present for constitutive models that are temperature dependent. For this example, the values
shown below will be used to calculate the thermal conductivity at a desired temperature.
Fi g u r e 1 9 - 3 1 : Co n d u ct i v i t y t a b o f W o r k p i e ce M a t e r i a l w i n d o w
To find the thermal conductivity at 20°C, first determine the conductivity ratio from the coefficients
defined within the Conductivity tab. For this example, R represents the conductivity ratio.
321
Tr a n sfe r
1 2 3 4 5
R= k0 + k1  T  + k2  T  + k3  T  + k4  T  + k5  T 
1 5 2
=  0.98311 +  0.0015461  20  +   – 2.7602 10   20 
8 3 11 4 5
+   8.1682 10   20  +   – 7.3092 10   20  +  0  20  
= 1.003632831
Next, the conductivity ratio needs to be multiplied by the baseline thermal conductivity to obtain
the thermal conductivity at 20°C.
K T  = R  K
=  1.003632831  100 
= 100.3633
At 20°C the thermal conductivity is 100.3633 W/m°C.
To determine the conductivity at other temperatures, simply replace 20°C in the above equations
with the desired temperature. The table below shows the conductivity ratio and thermal
conductivity varying as a function of temperature. When N/A is displayed for the ratio, it simply
means that the thermal conductivity is constant for this temperature. This occurs when the
temperature is greater than the maximum temperature defined or less than the reference
temperature defined.
Ta ble 1 9 .4 : Con du ct ivit y Ra t io a n d Th e r m a l Con du ct ivit y a s a Fu n ct ion of

Te m pe r a t u r e
Te m pe r a t u r e Con du ct ivit y Th e r m a l Con du ct ivit y

( ° C) Ra t io ( W / m ° C)
-40 N/A 94.0482
-30 N/A 94.0482
-20 0.9405 94.0482
0 0.9831 93.3110
10 0.9959 99.5892
20 1.0036 100.3633
40 1.0058 100.5829
100 0.9360 93.5991
200 0.7235 72.3451
300 0.5695 56.9509
400 0.5208 52.0802
500 0.4466 44.6585
510 N/A 44.6585
520 N/A 44.6585
530 N/A 44.6585
322
Re fe r e n ce s | St r e ss Upda t e For m u la t ion s
To visualize this trend a graph of the thermal conductivity versus temperature is shown below. The
green dashed line shows the reference temperature and the red dashed line shows the maximum
temperature.
Fi g u r e 1 9 - 3 2 : T h e r m a l co n d u ct i v i t y v s t e m p e r a t u r e t r e n d
19.8 — Stress Update Formulations
Rate Formulation (Jaumann Rate)
n+1 n n n t
 =  + · t + W  +  W
n
· = f    D 
Below, D is the deformation rate tensor and W is the spin tenser:
1 v v
D y = ---  --------i + --------i 

2 x j x j
1 v v
W y = ---  --------i – --------i 
2  x j x j
n
Below, t is the time step and  is the Cauchy stress:
n+1 n n n
 + f    D  t t  + W  +  W
The function f   in the above equation corresponds to the user-defined subroutine mat_user. The
n n
spin term W  +  W is applied outside of the mat_user subroutine.
323
n
D  t and  are transferred to the user-defined subroutine mat_user as deps(3,3) and sig(3,3),
n+1
respectively. User computes the updated Cauchy stress  and returns to sig(3,3).
Total Formulation (Deformation Gradient)
User is required to compute Cauchy stress sig(3,3) from deformation gradient eps(3,3). The
following sections provide examples of user-defined material total formulations:
KI N EM ATI CS
A local multiplicative decomposition of the deformation gradient is adopted.
e p
F  X  t  = F  X  t F  X  t (1)
The volume-preserving part of the deformation gradient is given by
–1  3
F = J F , where J = detF (2)
The elastic left Cauchy-Green tensor
e e eT
b = F F (3)
is related to the plastic deformation by
e p–1 T p pT p
b = FC F , where C = F F (4)
H YPERELASTI C RELATI ON SH I PS
The stress response is characterized by a stored-energy function of the form
e e
W = U  J  + W  b (5)
–2  3
e e e eT e e
b = J + F F  J = det F
Consider the energy function definition as follows:
e 1 2
U  J  = ---  1---  J e – 1  – 1nJ e (6)
2 2
e 1 e
W  b  = ---   tr  b  – 3 
2
324
where  denotes the bulk modulus and  denotes the shear modulus. The stress-strain
relationships read:
e
 = J p1 + s (7)
2
e
  J – 1
e
p = U  J  = --- ---------------------
2 Je
e
s = dev    = dev  b 
YI ELD CON D I TI ON
Classical Mises-Huber yield condition is formulated in terms of Kirchhoff stress
2
f     = dev    – ---   Y + K (8)
3
where  Y denotes the yield stress, K denotes the isotropic hardening modulus, and  denotes the
hardening parameter.
ASSOCI ATI VE FLOW RULE AN D H ARD EN I N G LAW
The flow rule in material description is given by:
 p 
–1
2 e –1 –T
-----  C  = – --- tr  b F nF ,(9)
t   3
s
n = ------- ,
s
–2  3 –2  3 T
p p p p p p
whereC = J C = J F F . The hardening rule reads:
2
· = ---  (10)
3
By applying the time stepping algorithm and pushing forward the flow rule given in Equation 9, the
spatial, discrete, evolution equations are obtained:
e e T 2 e
b n + 1 = f n + 1 b n f n + 1 – --- tr  b n + 1 n n + 1(11)
3
–1  3
f n + 1 =  det f n + 1  fn+
325
–1
f n + 1 = Fn + 1Fn
sn + 1
n n + 1 = ---------------
-
sn + 1
s n + 1 = dev   n + 1 
2
 n + 1 =  n + --- 
3
RETURN M APPI N G ALGORI TH M
For an incremental displacement field of the current configuration u n   n  X   , the updated

configuration is given by
x n + 1 =  n + 1  X  =  n  X  + u n   n  X  (12)
The total deformation gradient is
F n + 1 = D n + 1 (13)
with its volume-preserving part given by
–1  3
F n + 1 =  D n + 1 J n + 1 (14)
The trial elastic state is obtained by freezing the plastic flow as
p – 1 trial p–1
Cn + 1  = Cn (15)
trial
n + 1 = n
It is given by the following equations:
trial trial
 n + 1 = p n + 1 J n + 1 1 + s n + 1 (16)
trial e trial
s n + 1 = dev   b n + 1  
p n + 1 = U  J n + 1 
–1
e trial p T e T
bn + 1  = F n + 1 C n F n + 1 = f n + 1 bn f n +
trial
n + 1 = n
where the plastic deformation is assumed to be isochoric, i.e.
326
e
Jp = 1J = J
If the yielding condition is violated, the radial return algorithm is adopted and it admits that
e T 2 e trial trial
b = f n + 1 b n f n + 1 – --- tr   b n + 1  n n + 1(17)
3
ALGORI TH M D ESCRI PTI ON
The algorithm of the total formulation of the User-Defined Constitutive Model (2D Only) is
summarized on the following page. Given total deformation gradient, the Kirchhoff stress is
determined and further converted to Cauchy stress before returned to the engine. For this model,
e
user state variables include b and  .
Ret urn- Mapping Algorit hm for Finit e Deform at ion ( Tool Form ulat ion)
1. Update configuration
xn + 1 = xn + un configuration
f n + 1 = 1 +  x un relative deformation gradient
n
Fn + 1 = f n + 1Fn total deformation gradient

2. Construct elastic predictor
–1  3
f n + 1 =  det f n + 1  fn+
e trial e T
bn + 1  = f n + 1 bn f n + 1
trial e trial
s n + 1 = dev  b n + 1 
3. Check for plastic loading

Yield condition:
f n + 1 = s n + 1 – 2---   Y + K  n 
trial trial
3
trial
If f n + 1  0 , then
trial
Set  *  n + 1 =  *  n + 1 ; Go To 5.
Else Go To 4.
4. The return-mapping algorithm
I n + 1 = 1--- tr  b n + 1   and  = I e 
e e trial
Set
3   n+1
trial trial
f n + 1   2  sn + 1
Compute  = ----------------------------
- and n = ----------------
1 + K   3  trial
sn + 1
trial
Return map: s n + 1 = s n + 1 – 2n
2
 n + 1 =  n + --- 
3
Update intermediate configuration:
327
Re fe r e n ce s | 3 D Pa r a lle l Pr oce ssin g Con side r a t ion s
e e trial 2 e trial
bn + 1 =  bn + 1  – --- tr  b n + 1  nn + 1
3
5. Add elastic pressure term
Pressure: p n + 1 = U  J n + 1 J n + 1 = det F n + 1
Total stress:  n + 1 = p n + 1 J n + 1 1 + s n + 1
19.9 — 3D Parallel Processing Considerations

The speedup of Parallel Processing is limited by the sequential fraction of the code, the overhead of
creating and managing multiple threads, and the cost of synchronization between threads. For a
parallel program, as the number of threads used increases, the elapsed time of the parallel fraction
of the code decreases; on the other hand, the elapsed time of the sequential fraction of the code,
the multithreading overheads, and synchronization cost become the dominant factor in the total
elapsed time. As a result, the speedup of a parallel program, which is defined as the elapsed time
running in serial mode over in parallel mode, usually reaches a plateau beyond a certain number of
threads, as shown below.
Fi g u r e 1 9 - 3 3 : T o t a l e l a p se d t i m e o f t h r e e A d v a n t Ed g e 3 D b e n ch m a r k i n g ca se s
328
Fi g u r e 1 9 - 3 4 : P a r a l l e l sca l a b i l i t y o f t h r e e A d v a n t Ed g e 3 D b e n ch m a r k i n g ca se s
Simulations that are computationally intensive (typically drilling and milling with refined finite
element mesh, especially for the workpiece) benefit more from a higher number of threads being
run, as each thread has a significant workload to offset the overheads and cost of multithreading.
The figures above show how, of three AdvantEdge parallel benchmarking cases, the most
computationally intensive drilling case (which takes 118.94 hours running in serial mode) achieves
the most speedup - 18x - when run with 38 parallel threads. AdvantEdge 3D parallel capability
speeds up expensive computation most effectively.
Since the scalability may reach a plateau at high thread count, the efficiency of a parallel program
decreases. Depending on the scalability of a particular setup and the number of cases to be solved
for a Design of Experiment (DOE), users should decide the optimal parallel configuration to run the
battery to achieve the maximum throughput. For example, consider a case with an expected
parallel performance as shown below. If there is only one case in the DOE, the user should run it
with 16 threads and get results in 1 hour. However, if there are 4 cases in the DOE and they all have
similar parallel performance, the best throughput is achieved by running the four cases
simultaneously with 4 threads for each, getting all results in 2.33 hours. If user chooses to run the
DOE with 16 threads for one case at a time, the total elapsed time is 4 hours.
Fi g u r e 1 9 - 3 5 : Ex p e ct e d e l a p se d t i m e f o r e f f i ci e n cy st u d y e x a m p l e
329
Computer Configuration
Third Wave Systems has taken advantage of new processor architecture to enable enhanced
scalability for Parallel Processing. Based on the company’s benchmarking data, AdvantEdge has
better performance and scalability when used with newer Intel processors such as Nehalem and
Westmere (for more, see 3D Parallel Processing Considerations).
For this reason, Third Wave System has identified both recommended and minimum parallel
computing requirements, which are posted on its corporate website:
www.thirdwavesys.com/products/advantedge_requirements.htm
BIOS Setting
The Basic Input Output System (BIOS) is an essential set of routines in a PC that are stored on the
motherboad. This is a critical component of the computer, and some BIOS settings may impact the
performance of AdvantEdge Parallel Processing. Accessing the BIOS will differ depending on the
manufacture of the motherboard. Often time the difference is what key is necessary to push. The
usermanual for the motherboard can be handy to determine which key will access the BIOS. Some
keys that are usually used are F1, F2, and the Del key. Sometimes the motherboard will post this
information when the computer turns on. Turn on the computer system and press the key to access
the Bios. Sometimes it may be necessary to push the key more than once. Instead of the typical
boot screen, the BIOS screen should appear.
Hyperthreading
AdvantEdge Parallel Processing takes advantage of physical cores only. Some processor
architectures (e.g., Intel) provide Hyperthreading capabilities. Hyperthreading enables two logical
cores to utilize one physical core. The operating system does not distinguish between physical and
logical cores, and only sees these as total cores. It’s not to exceed the number of physical cores on
the computer running AdvantEdge FEM. If more cores are requested by AdvantEdge \than are
available, there will be degradation in performance (i.e., longer elapsed times) due to thread
contention for CPU-core time. AdvantEdge can run with Hyperthreading on or off as long as the
number of cores requested is not greater than the number of physical cores.
It is important to understand how many cores the computer has. A four core computer with
hyperthreading could appear to be an eight core computer. To run AdvantEdge, the user should turn
hyperthreading off and only run a maximum of four cores at a time on this type of workstation.
To turn Hyperthreading off, user need to reboot the computer and enter the BIOS setting.
Hyperthreading usually appears as Logical Processor in BIOS and it needs to be disabled.
330
Re fe r e n ce s | M a t e r ia l Pr ope r t ie s
Memory Setting
Most newer multicore platforms can utilize the Non-Uniform Memory Access (NUMA) to get faster
memory acess than traditional Uniform Memory Access (UMA) systems. However, AdvantEdge
Parallel Processing is currently not designed to utilize NUMA. It can run on a NUMA system but the
performance is not as repeatable as on a UMA system. To turn off NUMA, user can enter the BIOS
setting when the computer is rebooting and enable N o d e I n t e r l e a v e option in the BIOS Memory
System.
19.10 — Material Properties
Ta ble 1 9 .5 : W or k pie ce Pr ope r t ie s
UTS YS H a r dn e ss
W or k pie ce M a t e r ia l
( M pa ) ( M Pa ) ( H Rc) ( Bh n )
15-5PH (Project 7000) 986 334

15-5PH (XM-12) 1050 316
15-5PH SST (H1025) 1145 1110 36 352
15-5PH SST (H1100) 1069 1034 332
15-5PH SST (H1150) 896 717 30 311
15-5PH SST (H925) 1317 1213 43 409
17-4-PH SST 1365 1262 420
2205 Stainless Steel 760 515 272
300M 27 262
300M (550Bhn) 1970 1655 550
304 Stainless Steel 505 215 21 230
304L Stainless Steel 430 23
316L Stainless Steel 154
416 Stainless Steel 515 275 97 HRb 224
ASTM A182 Grade F55 Stainless 750 435 270
Steel
ASTM A705 Type 630 1070 664.5 313
M152 Stainless Steel 1104 960 326
465 Custom 40 370
331
( M pa ) ( M Pa ) ( H Rc) ( Bh n )
AE44 245 142 55.8

Aermet 100 1035 39 362
AISI 1020 395 295 111
AISI 1040 515 350 149
AISI 1045 207
AISI 1045 (200 Bhn) 394 200
AISI 1050 (Normalized) 752 425 24.5 253
AISI 1050 (Q&T) 924 676 32 297
AISI 1053 2560 2160 623
AISI 1060 625 370 179
AISI 1070 2530 2330 627
AISI 1095 965 570 32 305
AISI 1118 525 315 80 HRb 150
AISI 1538 850 580 266
AISI 15-B-32 29 276
AISI 4120 1335 910 248
AISI 4130 1089 883 29 277
AISI 4140 (198 Bhn) 655 415 198
AISI 4340 1300 1200 40 298
AISI 4340M 1031 41 380
AISI 50-B-35 1004 323
AISI 5160 (Normalized) 1025 650 297
AISI 5160 (Q&T) 1170 1070 297
AISI 52100 614
AISI 8617 Core Hardened (46HRc) 1551 46 437
AISI 8617 Core Hardened (59HRc) 2420 59 600
AISI 8617 Unhardened (78HRb) 814 78 HRb 143
AISI 8620 530 385 149
AISI 9310 907 571 254
Al 1100 110 105
Al 2014-O 185 95
Al 2024 -T4 440 303
Al 2024-T3511 170
Al 2024-T42 250
Al 2139-T8 157
Al 2219-T351 360 250
Al 2224-T3511 245
Al 2324-T39 324
332
( M pa ) ( M Pa ) ( H Rc) ( Bh n )
Al 319 130
Al 356 140 55
Al 357 121
Al 380 317 159
Al 383 310 150 88.3
Al 383 Max Sn 310 150 87.5
Al 384 331 165 85
Al 5052-H32 230 195
Al 5059-H131 112
Al 5083-H32 320 250
Al 5086-H34 325 255
Al 5454-H32 275 205
Al 5456-H24 370 280
Al 6061-T6 310 282
Al 7010 441
Al 7050 421
Al 7050-T7451 524 469 81 HRb 152
Al 7055-T7511 597
Al 7055-W51 190
Al 7075-0 183
Al 7075-T6 572 503
Al 7075-T651 572 503
Al 7075-T73 266
Al 7075-T76511 274
Al7085-T7452 175
Al 7150-T6511 560
Al 7449 550 208
Al 7475 - T7451 389.5 496 135
Al357 121.1
Al7085-T7452 174.8
Alloy MP35N 2027 1965
ASTM B-688 Stainless Steel 86 HRb 165
Brico3010 534
C37700 Brass 68 HRb
Carpenter Alloy A286 1007 703 310
CGI-Ferritic 235
CGI-Pearlitic 234
CP Ti Grade 2 344 275 80 HRb 150
333
( M pa ) ( M Pa ) ( H Rc) ( Bh n )
CP Ti Grade 3 440 377

CPM 9V 1930 573
CrMoV gun barrel Steel 1311 877 300
D2 Tool Steel 486 210
D3 Tool Steel 597
D4512 520 330 84 HRb 162
D5506 92 HRb 190
Ferralium 255 Forged 867 674 300
H13 (44) 1882 44 415
H13 (48) 1641 48 460
H13 (52) 1882 52 545
Hastelloy C-22 765 359 95 HRb 210
Hastelloy G-30 710 338 216
Hastelloy X 765 380 231
Haynes Alloy 242 257 200
HB3 447
HB7 452.2
IN100 40 375
Incoloy A286 300
Inconel 718 1613 1103 414
Inconel 718HS 1240 1036 420
Invar 717 679 121
Monel K500 285
MRI153 250 170 58.9
MRI230 235 180 61.3
Nb C-103 71 HRb
Ni Al Bronze 295 73 HRb
Nitralloy 910 793
Nodular 4010 215
PH13-8Mo 435
Rene 41 (R41) 1260 820 334
Rene 95 1620 1310 400
SAE5120 285
SAE 52100 182
SAEG1800 18 ksi 187
SAEG2500 25 ksi 200
SAEG3000 30 ksi 214
SAEG3500 35 ksi 231
334
( M pa ) ( M Pa ) ( H Rc) ( Bh n )
SAEG4000 40 ksi 243

Sonoston 82 HRb 150
SS2205 760 515 272
Ti 5Al-5V-5Mo-3Cr 39
Ti-10V-2Fe-3Al 1000
Ti-4Al-4Mo-2Sn 1100 940
Ti54M 990 304
Ti-5Al-2.5Sn ELI 775 725
Ti-5Al-2Sn-4Mo-2Zr-4Cr 1180 1100 378
Ti-6Al-2Fe-0.1Si 1000 960 330
Ti-6-2-4-2 36 335
Ti-6-2-4-6 40 375
Ti-6Al-4V 1050
Ti-6Al-4V ELI 860 790 305
Ti-6Al-6V-2Sn 1050
Tungsten 294.6
Udimet 720 1517 1104 43 401
Ultimet 1014 524 250
Waspaloy 1335 910 461
X53 1172 965 304.4
ZE41A 205 140 62
335
Re fe r e n ce s | Cr oss Re fe r e n ce for M a t e r ia l N a m e s
19.11 — Cross Reference for Material Names

Ta ble 1 9 .6 : Cr oss Re fe r e n ce for M a t e r ia l N a m e s
Un it e d St a t e s Gr e a t Br it a in Ja pa n Ge r m a n y Eu r ope Sw e de n Fr a n ce I n t e r n a t ion a l
15-5 PH (XM-12) 15-5-PH SST (US) 15-5-PH SST (US) WNr 1.4532; DIN X4CrNiCuNb164 (XM-12) X5CrNiCuNb14-5 (XM-12) 15-5-PH SST (US) 15-5-PH SST (US) 15-5-PH SST (US)
15-5PH (Custom 7000) 15-5-PH SST (US) 15-5-PH SST (US) WNr 1.4532; DIN X4CrNiCuNb164 X5CrNiCuNb14-5 15-5-PH SST (US) 15-5-PH SST (US) 15-5-PH SST (US)
15-5PH SST (H1025) 15-5-PH SST (H1025) (US) 15-5-PH SST (H1025) (US) WNr 1.4532; DIN X4CrNiCuNb164 (H1025) X5CrNiCuNb14-5 (H1025) 15-5-PH SST (H1025) (US) 15-5-PH SST (H1025) (US) 15-5-PH SST (H1025) (US)
17-4-PH (H900) SST 17-4-PH SST (US) SUS630 WNr 1.4542; DIN X5CrNiCuNb16-4 X5CrNiCuNb16-4 17-4-PH SST (US) AFNOR Z6CNU17.04 17-4-PH SST (US)
300M Steel 300M Steel (US) 300M Steel (US) 300M Steel (US) 300M Steel (US) 300M Steel (US) 300M Steel (US) 300M Steel (US)
300M Steel (550Bhn) 300M Steel (550Bhn) (US) 300M Steel (550Bhn) (US) 300M Steel (550Bhn) (US) 300M Steel (550Bhn) (US) 300M Steel (550Bhn) (US) 300M Steel (550Bhn) (US) 300M Steel (550Bhn) (US)
304 Stainless Steel BS 304S15 SUS304 WNr 1.4301; DIN X5CrNi18-11 X5CrNi18-10 SS 2332 AFNOR Z6CN18.09 ISO 683-13(74) 11
304L Stainless Steel BS 304S12 SUS304L WNr 1.4306; DIN GX2CrNiN18-9 X2CrNi19-11 SS 2352 AFNOR Z2CN18.10 ISO 683-13(74)
309 Stainless Steel BS 309 SUH309 WNr 1.4828; DIN X15CrNiSi20-12 309 Stainless Steel (US) 309 Stainless Steel (US) AFNOR Z15CN24.13 ISO 4955(94) H13
316 Stainless Steel 316S16 SUSF316 WNr 1.4401; DIN X5CrNiMo 17-12-2 X5CrNiMo 17-12-2 SS 2347 AFNOR Z6CnD17.11 ISO 2604-2(75) TS60
316L Stainless Steel 316S37 SUSF316L WNr 1.4404; DIN X2CrNiMo18-14-13 X2CrNiMo 18-14-13 SS 2348 AFNOR Z6CnD17.12 ISO 2604-1(75) F59
410 Stainless Steel BS 410 SUSF410 WNr 1.4006; DIN EN 10088(95) EN 10088/2(95) SS 2302 AFNOR Z12C13 ISO 683-13(74) 3
416 Stainless Steel BS 416S21 SUS416 WNr 1.4005; DIN EN 10088(95) EN 10088(95) SS 2380 AFNOR Z12CF13 ISO 683-13(74) 7
420 Stainless Steel BS 420 SUSF420 WNr 1.4021; DIN EN 10088(95) EN 10088/2(95) (1.4021 SS 2303 AFNOR Z20C13 ISO 683-13(74) 4
422 Stainless Steel 422 Stainless Steel (US) SUH616 422 Stainless Steel (US) 422 Stainless Steel (US) 422 Stainless Steel (US) 422 Stainless Steel (US) 422 Stainless Steel (US)
465 Custom Stainless Steel C465 (US) C465 (US) C465 (US) C465 (US) C465 (US) C465 (US) C465 (US)
ASTM A182 Grade F55 Stainless Steel ASTM A182 Grade F55 (US) ASTM A182 Grade F55 (US) ASTM A182 Grade F55 (US) ASTM A182 Grade F55 (US) ASTM A182 Grade F55 (US) ASTM A182 Grade F55 (US) ASTM A182 Grade F55 (US)
ASTM A705 Type 630 Stainless Steel ASTM A705 Type 630 (US) ASTM A705 Type 630 (US) ASTM A705 Type 630 (US) ASTM A705 Type 630 (US) ASTM A705 Type 630 (US) ASTM A705 Type 630 (US) ASTM A705 Type 630 (US)
M152 Stainless Steel M152 (US) M152 (US) M152 (US) M152 (US) M152 (US) M152 (US) M152 (US)
AE44 AE44 (US) AE44 (US) AE44 (US) AE44 (US) AE44 (US) AE44 (US) AE44 (US)
Aermet 100 Aermet 100 (US) Aermet 100 (US) Aermet 100 (US) Aermet 100 (US) Aermet 100 (US) Aermet 100 (US) Aermet 100 (US)
AISI 1020 BS 060A20 SWRCH20K WNr 1.0402; DIN C22 Fe430D1 SS 1450 AFNOR CC20 ISO 683-1(87) C20
AISI 1040 BS 080A40 STKM16A WNr 1.5120; DIN 38MnSi4 C40 AISI 1040 (US) AFNOR F60 ISO 683-1(87) C40
AISI 1045 BS 080M46 S45C WNr 1.0503; DIN Ck45 C45 SS 1650 AFNOR CC45 ISO 683-1(87) C45
AISI 1045 (200Bhn) BS 080M46 (200Bhn) S45C (200Bhn) WNr 1.0503; DIN Ck45 (200Bhn) C45 (200Bhn) SS 1650 (200Bhn) AFNOR CC45 (200Bhn) ISO 683-1(87) C45 (200Bhn)
AISI 1050 (Norm) 50CS (norm) S50C (norm) WNr 1.1241; DinCm50 (norm) C50 (norm) SIS 1674-03 (norm) AFNOR C50RR (norm) ISO 683-1(87) C50 (Q&T)
AISI 1050 (Q&T) 50CS (Q&T) S50C (Q&T) WNr 1.1241; DinCm50 (Q&T) C50 (Q&T) SIS 1674-03 (Q&T) AFNOR C50RR (Q&T) ISO 683-1(87) C50 (Q&T)
AISI 1053 BS 060A53 S53CM WNr 1.0601; DIN CK53 C53 SS 1676 AFNOR XC54 AISI 1053 (US)
AISI 1060 BS 060A62 S60CM WNr 1.0601; DIN CK60 C60 SS 1678 AFNOR CC55 ISO 683-1(87) C60
AISI 1070 BS 060A70 S70CM WNr 1.0601; DIN CK70 C70 SS 1770 AFNOR XC70 AISI 1070 (US)
AISI 1095 BS 060A96 S95CM WNr 1.1275; DIN CK100 C98D2 SS 1870 AFNOR XC100 AISI 1095 (US)
AISI 1118 AISI-1118 (US) AISI-1118 (US) AISI-1118 (US) AISI-1118 (US) AISI-1118 (US) AISI-1118 (US) AISI-1118 (US)
AISI 15-B-35 AISI 15-B-35 (US) AISI 15-B-35 (US) AISI 15-B-35 (US) AISI 15-B-35 (US) AISI 15-B-35 (US) AISI 15-B-35 (US) AISI 15-B-35 (US)
AISI 4120 708M20 SCM420H WNr 1.7211; DIN 23CrMoB4 AISI 4120 (US) AISI 4120 (US) AFNOR 25M4 AISI 4120 (US)
AISI 4130 708A40 SCM430 WNr 1.7218; DIN 25CrMo4 25CrMo4 SS 2225 AFNOR 24CD4 ISO 683-4 type 2
AISI 4140 (198 Bhn) 708M40 SCM440H WNr 1.7225; DIN 42CrMo4 42CRMo4 SS 2244 AFNOR 43CD4 ISO 683-4 Type 3a
AISI 4340 818M40 SNCM439 WNr 1.6565; DIN 40 NiCrMo6 34CrNiMo6 SS 2541 AFNOR 35NCD6 ISO 683-8 4
AISI 4340M 818M40 (Modified) SNCM439 (Modified) WNr 1.6565; DIN 40 NiCrMo6 (Modified) 34CrNiMo6 (Modified) SS 2541 (Modified) AFNOR 35NCD6 (Modified) ISO 683-8 4 (Modified)
AISI 50-B-35 AISI 50-B-35 (US) SMNNC3 WNr 1.7007; DIN 37CrB1 39MnCrB6-2 AISI 50-B-35 (US) AFNOR 38CBi AISI 50-B-35 (US)
AISI 5160 (norm) 527A60 (norm) SUP 9A (norm) WNr 1.7176; DIN 55Cr70 (norm) AISI 5160 (norm)(US) SS 2254 (norm) AFNOR 55C3 (norm) ISO 683-14(92) 55Cr3 (norm)
AISI 5160 (Q&T) 527A60 (Q&T) SUP 9A (Q&T) WNr 1.7176; DIN 55Cr70 (Q&T) AISI 5160 (Q&T)(US) SS 2254 (Q&T) AFNOR 55C3 (Q&T) ISO 683-14(92) 55Cr3 (Q&T)
AISI 52100 BS 535A99 E52100 (US) WNr 1.3505; DIN 100Cr6 E52100 SS 2258 AFNOR 100C6 ISO 683-17(76)
336

AISI 8617 (46HRc) 785M19 (46HRc) SNCM21H (46HRc) AISI 8617 (US) (46HRc) AISI 8617 (US) (46HRc) SS 2506 (46HRc) AFNOR 15NCD2 (46HRc) AISI 8617 (US) (46HRc)
AISI 8617 (59HRc) 785M19 (59HRc) SNCM21H (59HRc) AISI 8617 (US) (59HRc) AISI 8617 (US) (59HRc) SS 2506 (59HRc) AFNOR 15NCD2 (59HRc) AISI 8617 (US) (59HRc)
AISI 8617 (78HRb) 785M19 (78HRb) SNCM21H (78HRb) AISI 8617 (US) (78HRb) AISI 8617 (US) (78HRb) SS 2506 (78HRb) AFNOR 15NCD2 (78HRb) AISI 8617 (US) (78HRb)
AISI 8620 BS 806M20 SNCM21 WNr 1.6523; DIN 20NiCrMo2-2 20NiCrMo2-2 SS 2506 AFNOR 20NCD2 ISO 683-17(76) 12
AISI 9310 AISI 9310 (US) AISI 9310 (US) AISI 9310 (US) AISI 9310 (US) AISI 9310 (US) AISI 9310 (US) AISI 9310 (US)
Al 1100 Al 1100 (US) 1100 Al 1100 (US) Al 1100 (US) Al 1100 (US) NF A50451 1100(A45) ISO TR2136 Al99.0Cu
Al 2014-O Al 2014-O (US) 2014 3.1255/AlCuSiMn Al 2014-O (US) Al 2014-O (US) NF A50451 2014 Al-Cu4SiMg
Al 2024-T3511 Al 2024-T3511 (US) 2024-T3511 3.1355/AlCuMg2-T3511 Al 2024-T3511 (US) Al 2024-T3511 (US) NF A50506 2024 Al-Cu4Mg1 (T3511)
Al 2024-T4 Al 2024-T4 (US) 2024 3.1355/AlCuMg2 Al 2024-T4 (US) Al 2024-T4 (US) NF A50506 2024 Al-Cu4Mg1 (T4)
Al 2024-T42 Al 2024-T42 (US) 2024-T42 3.1355/AlCuMg2-T42 Al 2024-T42 (US) Al 2024-T42 (US) NF A50506 2024 Al-Cu4Mg1 (T42)
Al 2139-T8 Al 2139-T8 (US) Al 2139-T8 (US) Al 2139-T8 (US) Al 2139-T8 (US) Al 2139-T8 (US) Al 2139-T8 (US) Al 2139-T8 (US)
Al 319 LM4 AC2B Al 319 (US) Al 319 (US) 4230-00 Al 319 (US) Al -Si5Cu3Fe
Al 356 LM25 AC4C 3.0861/V/AlTi5B1 Al 356 (US) Al 356 (US) Al 356 (US) 356
Al 380 Al 380 (US) ADC10 GK-AlSi10Mg(Cu)wa/3. Al 380 (US) 4252-10 AL 380 (US) 380
Al 383 Al 383 (US) ADC12Z Al 383 (US) Al 383 (US) Al 383 (US) Al 383 (US) Al 383 (US)
Al 383 Max Sn Al 383 Max Sn (US) ADC12Z Max Sn Al 383 Max Sn (US) Al 383 Max Sn (US) Al 383 Max Sn (US) Al 383 Max Sn (US) Al 383 Max Sn (US)
Al 384 Al 384 (US) ADC12 Al 384 (US) Al 384 (US) Al 384 (US) Al 384 (US) Al 384 (US)
Al 5052-H32 Al 5052-H32 (US) 5052 3.3523/AlMg2.5 Al 5052-H32 (US) 4120-00 NF A50411 5052 Al-Mg2
Al 5059-H131 Al 5059-H131 (US) Al 5059-H131 (US) Al 5059-H131 (US) Al 5059-H131 (US) Al 5059-H131 (US) Al 5059-H131 (US) Al 5059-H131 (US)
Al 6061-T6 6061(H20) 6061 3.3326/AlMg1.8 Al-6061-T6 (US) Al-6061-T6 (US) NF A50411 6061 Al-Mg1SiCu
Al 7010 Al 7010 (US) Al 7010 Al 7010 Al 7010 (US) Al 7010 (US) Al 7010 (US) Al 7010 (US)
Al 7050 Al7050 (US) Al 7050 Al 7050 Al7050 (US) Al7050 (US) Al 7050 (US) Al7050 (US)
Al 7075-0 Al-7075-0 (US) Al 7075-0 Al-7075-0 (US) Al-7075-0 (US) Al7075-0 (US) Al-7075-0 (US) Al-7075-0 (US)
Al 7075-T6 Al-7075-T6 (US) Al 7075-T6 Al-7075-T6 (US) Al-7075-T6 (US) Al7075-T6 (US) Al-7075-T6 (US) Al-7075-T6 (US)
Al 7449 Al 7449 Al 7449 Al 7449 Al 7449 Al 7449 Al 7449 Al 7449
Al357 Al357 (US) Al357 (US) Al357 (US) Al357 (US) Al357 (US) Al357 (US) 357
Al7050-T7451 Al7050-T7451 (US) Al7050-T7451 (US) Al7050-T7451 (US) Al7050-T7451 (US) Al7050-T7451 (US) Al7050-T7451 (US) Al7050-T7451 (US)
Al7055-W51 Al7055-W51 (US) Al7055-W51 (US) Al7055-W51 (US) Al7055-W51 (US) Al7055-W51 (US) Al7055-W51 (US) Al7055-W51 (US)
Al7085-T7452 Al7085-T7452 (US) Al7085-T7452 (US) Al7085-T7452 (US) Al7085-T7452 (US) Al7085-T7452 (US) Al7085-T7452 (US) Al7085-T7452 (US)
Alloy MP35N Alloy MP35N (US) Alloy MP35N (US) Alloy MP35N (US) Alloy MP35N (US) Alloy MP35N (US) Alloy MP35N (US) Alloy MP35N (US)
ASTM B-688 Stainless Steel ASTM B-688 (US) ASTM B-688 (US) ASTM B-688 (US) ASTM B-688 (US) ASTM B-688 (US) ASTM B-688 (US) ASTM B-688 (US)
Brico3010 Brico3010 Brico3010 Brico3010 Brico3010 Brico3010 Brico3010 Brico3010
C37700 Brass C37700 Brass (US) JIS C3771 C37700 Brass (US) C37700 Brass (US) C37700 Brass (US) C37700 Brass (US) C37700 Brass (US)
Carpenter Alloy A286 Carpenter Alloy A286 (US) Carpenter Alloy A286 (US) Carpenter Alloy A286 (US) Carpenter Alloy A286 (US) Carpenter Alloy A286 (US) Carpenter Alloy A286 (US) Carpenter Alloy A286 (US)
CGI-Ferritic CGI-Ferritic CGI-Ferritic CGI-Ferritic CGI-Ferritic CGI-Ferritic CGI-Ferritic CGI-Ferritic
337

CGI-Pearlitic CGI-Pearlitic CGI-Pearlitic CGI-Pearlitic CGI-Pearlitic CGI-Pearlitic CGI-Pearlitic CGI-Pearlitic
CP Ti Grade 3 CP Ti Grade 3 (US) TB 35 Class 3 3.7065 DIN 17850 CP Ti Grade 3 (US) CP Ti Grade 3 (US) CP Ti Grade 3 (US) CP Ti Grade 3 (US)
CP Titanium Grade 2 BS 2TA TB 35 Class 2 3.7035 DIN 17860 TI-P02 Ti Grade 2 (US) Ti Grade 2 (US) Ti Grade 2 (US)
CPM 9V CPM 9V CPM 9V CPM 9V CPM 9V CPM 9V CPM 9V CPM 9V
CrMoV gun barrel Steel CrMoV gun barrel Steel (US) CrMoV gun barrel Steel (US) CrMoV gun barrel Steel (US) CrMoV gun barrel Steel (US) CrMoV gun barrel Steel (US) CrMoV gun barrel Steel (US) CrMoV gun barrel Steel (US)
D2 Tool Steel BD2 SKD11 WNr 1.2609; DIN X165CrVMo121 D2 Tool Steel (US) SS 2310 AFNOR Z160CDV12 D2 Tool Steel (US)
D3 Tool Steel BD3 SKD1 WNr 1.2436; DIN X210CrW12 D3 Tool Steel (US) SS 2314 ANFOR Z200C12 D3 Tool Steel (US)
D4512 BS 420/12 JIS FCD40 Class1 D4512 (US) D4512 (US) D4512 (US) D4512 (US) D4512 (US)
D5506 BS 2789 500/7 JIS G5502 FCD600 DIN WNr. 0.7050 D5506 (US) SIS 140727 0727-02 AFNOR NFA32201 ISO 1083(87)
Ferralium 255 Forged Ferralium 255 Forged (US) Ferralium 255 Forged (US) Ferralium 255 Forged (US) Ferralium 255 Forged (US) Ferralium 255 Forged (US) Ferralium 255 Forged (US) Ferralium 255 Forged (US)
H13 (44) BH13 (44) SKD61 (44) Wnr 1.2344; DIN GX40CrMoV5-1 (44) H13 (US) (44) SS242 (44) AFNOR Z40CDV5 (44) H13 (US) (44)
Hastelloy C-22 Hastelloy C-22 (US) Hastelloy C-22 (US) Hastelloy C-22 (US) Hastelloy C-22 (US) Hastelloy C-22 (US) Hastelloy C-22 (US) Hastelloy C-22 (US)
Hastelloy G-30 Hastelloy G-30 (US) Hastelloy G-30 (US) Hastelloy G-30 (US) Hastelloy G-30 (US) Hastelloy G-30 (US) Hastelloy G-30 (US) Hastelloy G-30 (US)
Hastelloy X NA40 Hastelloy X (US) Hastelloy X (US) Hastelloy X (US) Hastelloy X (US) Hastelloy X (US) Hastelloy X (US)
Haynes Alloy 242 Haynes Alloy 242 (US) Haynes Alloy 242 (US) Haynes Alloy 242 (US) Haynes Alloy 242 (US) Haynes Alloy 242 (US) Haynes Alloy 242 (US) Haynes Alloy 242 (US)
HB3 HB3 (US) HB3 (US) HB3 (US) HB3 (US) HB3 (US) HB3 (US) HB3 (US)
HB7 HB7 (US) HB7 (US) HB7 (US) HB7 (US) HB7 (US) HB7 (US) HB7 (US)
IN100 IN100 (US) IN100 (US) IN100 (US) IN100 (US) IN100 (US) IN100 (US) IN100 (US)
Incoloy A286 Incoloy A286 (US) Incoloy A286 (US) Incoloy A286 (US) Incoloy A286 (US) Incoloy A286 (US) Incoloy A286 (US) Incoloy A286 (US)
Inconel 718 Inconel 718 (US) Inconel 718 (US) Inconel 718 (US) Inconel 718 (US) Inconel 718 (US) Inconel 718 (US) Inconel 718 (US)
Inconel 718HS Inconel 718HS (US) Inconel 718HS (US) Inconel 718HS (US) Inconel 718HS (US) Inconel 718HS (US) Inconel 718HS (US) Inconel 718HS (US)
Invar Invar (US) Invar (US) Invar (US) Invar (US) Invar (US) Invar (US) Invar (US)
J431 G1800 G1800 (US) FC100 DIN GG150HB G1800 (US) SS 212 G1800 (US) G1800 (US)
J431 G3500 G3500 (US) FC250 G3500 (US) G3500 (US) G3500 (US) G3500 (US) G3500 (US)
J431G4000 G4000 (US) FC350 DIN GG220HB G4000 (US) SS 223 G4000 (US) G4000 (US)
Monel K500 Monel K500 (US) Monel K500 (US) Monel K500 (US) Monel K500 (US) Monel K500 (US) Monel K500 (US) Monel K500 (US)
MRI153 MRI153 (US) MRI153 (US) MRI153 (US) MRI153 (US) MRI153 (US) MRI153 (US) MRI153 (US)
MRI230 MRI230 (US) MRI230 (US) MRI230 (US) MRI230 (US) MRI230 (US) MRI230 (US) MRI230 (US)
Nb C-103 Nb C-103 (US) Nb C-103 (US) Nb C-103 (US) Nb C-103 (US) Nb C-103 (US) Nb C-103 (US) Nb C-103 (US)
Ni Al Bronze (UNS C63200) BS 2872 CA104 H3100 C6280 Ni Al Bronze (US) Ni Al Bronze (US) Ni Al Bronze (US) Ni Al Bronze (US) ISO 1640 CuAl10Fe5Ni5
Nitralloy Nitralloy (US) Nitralloy (US) Nitralloy (US) Nitralloy (US) Nitralloy (US) Nitralloy (US) Nitralloy (US)
Nodular 4010 Nodular 4010 (US) Nodular 4010 (US) Nodular 4010 (US) Nodular 4010 (US) Nodular 4010 (US) Nodular 4010 (US) Nodular 4010 (US)
PH13-8Mo PH13-8Mo (US) PH13-8Mo (US) PH13-8Mo (US) PH13-8Mo (US) PH13-8Mo (US) PH13-8Mo (US) PH13-8Mo (US)
Rene 41 (R41) Rene 41 (US) Rene 41 (US) Rene 41 (US) Rene 41 (US) Rene 41 (US) Rene 41 (US) Rene 41 (US)
Rene 95 Rene 95 (US) Rene 95 (US) Rene 95 (US) Rene 95 (US) Rene 95 (US) Rene 95 (US) Rene 95 (US)
SAE 52100 BS 535A99 E52100 (US) WNr 1.3505; DIN 100Cr6 E52100 SS 2258 AFNOR 100C6 ISO 683-17(76)
SAE5120 SAE5120 (US) JIS G4052 SAE5120 (US) EN 10084 SAE5120 (US) SAE5120 (US) SAE5120 (US)
Sonoston Sonoston Sonoston Sonoston Sonoston Sonoston Sonoston Sonoston
SS2205 SS2205 (US) SS2205 (US) SS2205 (US) SS2205 (US) SS2205 (US) SS2205 (US) SS2205 (US)
Ti 5Al-5V-5Mo-3Cr Ti 5Al-5V-5Mo-3Cr (US) Ti 5Al-5V-5Mo-3Cr (US) Ti 5Al-5V-5Mo-3Cr (US) Ti 5Al-5V-5Mo-3Cr (US) Ti 5Al-5V-5Mo-3Cr (US) Ti 5Al-5V-5Mo-3Cr (US) Ti 5Al-5V-5Mo-3Cr (US)
Ti 6Al-2Sn-4Zr-2Mo Ti 6Al-2Sn-4Zr-2Mo (US) Ti 6Al-2Sn-4Zr-2Mo (US) Ti 6Al-2Sn-4Zr-2Mo (US) Ti 6Al-2Sn-4Zr-2Mo (US) Ti 6Al-2Sn-4Zr-2Mo (US) Ti 6Al-2Sn-4Zr-2Mo (US) Ti 6Al-2Sn-4Zr-2Mo (US)
Ti 6Al-2Sn-4Zr-6Mo Ti 6Al-2Sn-4Zr-6Mo (US) Ti 6Al-2Sn-4Zr-6Mo (US) Ti 6Al-2Sn-4Zr-6Mo (US) Ti 6Al-2Sn-4Zr-6Mo (US) Ti 6Al-2Sn-4Zr-6Mo (US) Ti 6Al-2Sn-4Zr-6Mo (US) Ti 6Al-2Sn-4Zr-6Mo (US)
Ti-10V-2Fe-3Al Ti-10V-2Fe-3Al (US) Ti-10V-2Fe-3Al (US) Ti-10V-2Fe-3Al (US) Ti-10V-2Fe-3Al (US) Ti-10V-2Fe-3Al (US) Ti-10V-2Fe-3Al (US) Ti-10V-2Fe-3Al (US)
Ti-4Al-4Mo-2Sn Ti-4Al-4Mo-2Sn (US) Ti-4Al-4Mo-2Sn (US) Ti-4Al-4Mo-2Sn (US) Ti-4Al-4Mo-2Sn (US) Ti-4Al-4Mo-2Sn (US) Ti-4Al-4Mo-2Sn (US) Ti-4Al-4Mo-2Sn (US)
338
Re fe r e n ce s | M a t e r ia l Com posit ion s

Ti54M Ti54M (US) Ti54M (US) Ti54M (US) Ti54M (US) Ti54M (US) Ti54M (US) Ti54M (US)
Ti-5Al-2.5Sn ELI Ti-5Al-2.5Sn ELI (US) Ti-5Al-2.5Sn ELI (US) Ti-5Al-2.5Sn ELI (US) Ti-5Al-2.5Sn ELI (US) Ti-5Al-2.5Sn ELI (US) Ti-5Al-2.5Sn ELI (US) Ti-5Al-2.5Sn ELI (US)
Ti-5AL-2Sn-4Mo-2Zr-4Cr Ti-5AL-2Sn-4Mo-2Zr-4Cr (US) Ti-5AL-2Sn-4Mo-2Zr-4Cr (US) Ti-5AL-2Sn-4Mo-2Zr-4Cr (US) Ti-5AL-2Sn-4Mo-2Zr-4Cr (US) Ti-5AL-2Sn-4Mo-2Zr-4Cr (US) Ti-5AL-2Sn-4Mo-2Zr-4Cr (US) Ti-5AL-2Sn-4Mo-2Zr-4Cr (US)
Ti-6Al-2Fe-0.1Si Ti-6Al-2Fe-0.1Si (US) Ti-6Al-2Fe-0.1Si (US) Ti-6Al-2Fe-0.1Si (US) Ti-6Al-2Fe-0.1Si (US) Ti-6Al-2Fe-0.1Si (US) Ti-6Al-2Fe-0.1Si (US) Ti-6Al-2Fe-0.1Si (US)
Ti-6Al-4V Ti-6Al-4V (US) Ti-6Al-4V (US) Ti-6Al-4V (US) Ti-6Al-4V (US) Ti-6Al-4V (US) Ti-6Al-4V (US) Ti-6Al-4V (US)
Ti-6Al-4V ELI Ti-6Al-4V ELI (US) Ti-6Al-4V ELI (US) Ti-6Al-4V ELI (US) Ti-6Al-4V ELI (US) Ti-6Al-4V ELI (US) Ti-6Al-4V ELI (US) Ti-6Al-4V ELI (US)
Ti-6Al-6V-2Sn Ti-6Al-6V-2Sn (US) Ti-6Al-6V-2Sn Ti-6Al-6V-2Sn (US) Ti-6Al-6V-2Sn (US) Ti-6Al-6V-2Sn (US) Ti-6Al-6V-2Sn (US) Ti-6Al-6V-2Sn (US)
Tungsten Tungsten Tungsten Tungsten Tungsten Tungsten Tungsten Tungsten
Udimet720 Udimet720 Udimet720 Udimet720 Udimet720 Udimet720 Udimet720 Udimet720
Ultimet Ultimet (US) Ultimet (US) Ultimet (US) Ultimet (US) Ultimet (US) Ultimet (US) Ultimet (US)
Waspaloy Waspaloy Waspaloy (US) Waspaloy (US) Waspaloy (US) Waspaloy (US) Waspaloy (US) Waspaloy (US)
X53 X53 (US) X53 (US) X53 (US) X53 (US) X53 (US) X53 (US) X53 (US)
ZE41A ZE41A (US) ZE41A (US) ZE41A (US) AECMA prEN 2738 ZE41A (US) ZE41A (US) ISO 2119
19.12 — Material Compositions
Ta ble 1 9 .7 : M a t e r ia l Com posit ion : Alu m in u m s

Al Cr Cu Fe Mg Mn Ni Ot h e r Si Sn Ti V Zn Zr Ag
( D e sign a t ion
m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax
Al 1100 Balance 0.050 0.200 0.050 0.15 0.950 0.100
Al 2014-O Balance 0.100 3.900 5.000 0.700 0.200 0.800 0.400 1.200 0.15 0.500 1.200 0.150 0.250
Al 2024 -T4 Balance 4.350 0.500 1.500 0.600 0.150 0.500 0.150 0.250
Al 2024-T3511 Balance 4.350 0.500 1.500 0.600 0.150 0.500 0.150 0.250
Al 2024-T42 Balance 4.350 0.500 1.500 0.600 0.150 0.500 0.150 0.250
Al 2139-T8 Balance 0.050 4.500 5.500 0.150 0.200 0.800 0.200 0.600 0.100 0.100 0.250 0.150 0.600
Al 2219-T351 Balance 5.800 6.800 0.300 0.020 0.200 0.400 0.150 0.200 0.020 0.100 0.100 0.100 0.100 0.250
Al 2224-T3511 Balance 0.100 3.800 4.400 0.150 1.200 1.800 0.300 0.900 0.150 0.120 0.150 0.250
Al 2324-T39 Balance 0.100 3.800 4.400 0.120 1.200 1.800 0.300 0.900 0.150 0.100 0.150 0.250
Al 319 Balance 3.000 4.000 1.000 0.100 0.500 0.350 0.500 5.500 6.500 0.250 1.000
Al 356 Balance 0.250 0.600 0.200 0.450 0.350 0.150 6.500 7.500 0.250 0.350
Al 357 Balance 0.050 0.150 0.525 0.030 0.150 6.000 8.000 0.200 0.050
Al 380 Balance 3.000 4.000 2.000 0.100 0.500 0.500 0.500 7.500 9.500 0.350 3.000
Al 383 Balance 2.000 3.000 1.300 0.100 0.500 0.300 0.500 9.500 11.500 0.150 3.000
Al 383 Max Sn Balance 2.000 3.000 1.300 0.100 0.500 0.300 0.500 9.500 11.500 0.300 3.000
Al 384 Balance 3.000 4.500 1.300 0.100 0.500 0.500 0.500 10.500 12.000 0.350 3.000
Al 5052-H32 Balance 0.150 0.350 0.100 0.400 2.200 2.800 0.100 0.150 0.250 0.100
Al 5059-H131 Balance 0.250 0.250 0.500 5.000 6.000 0.600 1.200 0.150 0.450 0.200 0.400 0.900 0.050 0.250
Al 5083-H32 Balance 0.050 0.250 0.100 0.400 4.000 4.900 0.400 1.000 0.150 0.400 0.150 0.250
Al 5086-H34 Balance 0.050 0.250 0.100 0.500 3.500 4.500 0.200 0.700 0.150 0.400 0.150 0.250
339
Ta ble 1 9 .7 : M a t e r ia l Com posit ion : Alu m in u m s

Al Cr Cu Fe Mg Mn Ni Ot h e r Si Sn Ti V Zn Zr Ag
( D e sign a t ion
Al 5454-H32 Balance 0.050 0.200 0.100 0.400 2.400 3.000 0.500 1.000 0.150 0.250 0.200 0.250
Al 5456-H24 Balance 0.050 0.200 0.100 0.400 4.700 5.500 0.500 1.000 0.150 0.250 0.200 0.250
Al 6061-T6 Balance 0.040 0.350 0.150 0.400 0.700 8.000 1.200 0.150 0.150 0.400 0.800 0.150 0.250
Al 7010 Balance 0.050 1.500 2.000 0.150 2.100 2.600 0.100 0.050 0.150 0.120 0.060 5.700 6.700 0.100 0.160
Al 7050 Balance 0.040 2.000 2.600 0.150 1.900 2.600 0.100 0.150 0.120 0.060 5.700 6.700 0.080 0.150
Al 7050-T7451 Balance 0.040 2.000 2.600 0.150 1.900 2.600 0.100 0.150 0.120 0.060 5.700 6.700 0.080 0.150
Al 7055-T7511 Balance 0.040 2.000 2.600 0.150 1.800 2.300 0.050 0.150 0.100 0.060 7.600 8.400 0.080 0.250
Al 7055-W51 Balance 0.040 2.000 2.600 0.150 1.800 2.300 0.050 0.150 0.100 0.060 7.600 8.400 0.080 0.250
Al 7075-0 Balance 0.180 0.280 1.200 2.000 0.500 2.100 2.900 0.300 0.150 0.400 0.200 5.100 6.100
Al 7075-T6 Balance 0.180 0.280 1.200 2.000 0.500 2.100 2.900 0.300 0.150 0.400 0.200 5.100 6.100
Al 7075-T651 Balance 0.180 0.280 1.200 2.000 0.500 2.100 2.900 0.300 0.150 0.400 0.200 5.100 6.100
Al 7075-T73 Balance 0.180 0.280 1.200 2.000 0.500 2.100 2.900 0.300 0.150 0.400 0.200 5.100 6.100
Al 7075-T76511 Balance 0.180 0.280 1.200 2.000 0.500 2.100 2.900 0.300 0.150 0.400 0.200 5.100 6.100
Al 7085-T7452 Balance 1.300 2.000 0.080 1.200 1.800 0.060 7.000 8.000 0.120
Al 7150-T6511 Balance 0.040 1.900 2.500 0.150 2.000 2.700 0.100 0.150 0.120 0.060 5.900 6.900 0.080 0.115
Al 7449 Balance 1.400 2.100 0.150 1.800 2.700 0.200 0.150 0.120 0.250 7.500 8.700 0.250
Al 7475 - T7451 Balance 0.180 0.250 1.200 1.900 0.120 1.900 2.600 0.060 0.150 0.100 0.060 5.200 6.200
Ta ble 1 9 .8 : M a t e r ia l Com posit ion : N ick e ls

Al B C Co Cr Cu Fe Mn Mo N Nb Ni P S Si Ti V W Zr
( D e sign a t ion )
m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax
Alloy MP35N 0.010 0.025 33.000 19.000 21.000 1.000 0.150 9.000 10.500 Balance 0.015 0.010 0.150 1.000
Hastelloy C-22 0.010 2.500 22.000 3.000 0.500 13.000 Balance 0.080 0.350 3.000
Hastelloy G-30 0.030 5.000 28.000 31.500 1.000 2.400 13.000 17.000 1.500 4.000 6.000 Balance 0.040 0.020 0.800 1.500 4.000
Hastelloy X 0.008 0.100 1.500 22.000 18.000 1.000 9.000 Balance 1.000 0.600
Haynes Alloy 242 0.500 0.006 0.030 2.500 7.000 9.000 0.500 2.000 0.800 24.000 26.000 Balance 0.800
IN100 5.500 0.015 0.175 15.000 9.500 1.000 0.200 3.000 Balance 0.015 0.200 4.750 0.950 0.060
Inconel 718 0.500 0.006 0.080 1.000 17.000 21.000 0.300 17.000 0.350 2.800 3.300 4.750 5.500 Balance 0.350 0.650 1.150
Inconel 718HS 0.500 0.006 0.080 1.000 17.000 21.000 0.300 17.000 0.350 2.800 3.300 0.010 4.750 5.500 Balance 0.015 0.350 0.650 1.150
Monel K500 2.300 3.150 0.250 27.000 33.000 2.000 1.500 Balance 0.010 0.500 0.350 0.850
Rene 41 1.600 0.007 0.060 11.000 19.000 3.000 9.750 Balance 3.150
Rene 95 3.300 3.700 0.006 0.015 0.040 0.090 7.000 9.000 12.000 14.000 3.300 3.700 3.300 3.700 Balance 2.300 2.700 3.300 3.700 0.030 0.070
Udimet 720 2.500 0.020 0.015 14.750 18.000 3.000 Balance 5.000 1.250 0.040
Ultimet 0.060 54.000 26.000 3.000 0.800 5.000 0.080 Balance 0.300 2.000
Waspaloy 1.500 0.060 0.080 13.500 19.000 2.000 0.100 4.300 Balance 0.150 3.000 0.050
Ta ble 1 9 .9 : M a t e r ia l Com posit ion : St e e ls

Al B C Co Cr Cu Fe Mn Mo N N b + Ta Ni P S Si Ti V W
m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax
15-5 PH (XM-12) 0.070 14.800 3.500 Balance 1.000 0.300 3.500 5.500 0.040 0.030 1.000
15-5PH (Project 7000) 0.070 14.800 3.500 Balance 1.000 0.300 4.500 0.040 0.030 1.000
15-5-PH SST (Any Hardness) 0.070 14.800 3.500 Balance 1.000 0.300 4.500 0.040 0.030 1.000
340

17-4-PH SST 0.002 0.027 0.050 15.210 3.470 Balance 0.630 0.100 4.440 0.028 0.026 0.430 0.002
300M Steel (Any Hardness) 0.400 0.460 0.700 0.950 Balance 0.650 0.900 0.300 0.450 1.650 2.000 0.035 0.040 1.450 1.800 0.050
304 Stainless Steel 0.080 18.000 20.000 Balance 2.000 8.000 10.500 0.045 0.030 1.000
304L Stainless Steel 0.030 18.000 20.000 Balance 2.000 8.000 12.000 0.045 0.030 1.000
309 Stainless Steel 0.200 23.000 Balance 2.000 14.000 0.045 0.030 1.000
316 Stainless Steel 0.080 16.000 18.000 Balance 2.000 2.000 3.000 10.000 14.000 0.045 0.030 1.000
316L Stainless Steel 0.300 16.000 18.000 Balance 2.000 2.000 3.000 10.000 14.000 0.050 0.030 1.000
410 Stainless Steel 0.150 12.500 Balance 1.000 0.040 0.030
416 Stainless Steel 0.150 13.000 Balance 1.250 0.600 0.060 0.150 1.000
420 Stainless Steel 0.150 13.000 Balance 1.000 0.040 0.030 1.000
422 Stainless Steel 0.200 0.250 12.000 Balance 1.000 1.000 0.750 0.030 0.030 0.080 0.230
465 Custom Stainless Steel 0.020 11.000 12.500 Balance 0.250 0.750 1.250 10.750 11.250 0.015 0.010 0.250 1.500 1.800
ASTM A182 Grade F55 Stainless 0.021 25.800 0.600 0.540 3.500 0.250 0.030 7.300 0.027 0.003 0.410 0.670
Steel (Nb)
ASTM A705 Type 630 Stainless 0.070 15.0- 3.0-5.0 1.00 0.15- 3.0-5.0 0.025 0.015 1.00 0.050
Steel 16.5 0.45
M152 Stainless Steel 0.120 16.800 Balance 0.700 1.800 0.030 2.500 0.013 0.013 0.180 0.330
Aermet 100 0.230 13.400 3.100 Balance 1.200 11.100
AISI 1020 0.170 0.230 Balance 0.300 0.600 0.040 0.050
AISI 1040 0.370 0.440 Balance 0.600 0.900 0.040 0.050
AISI 1045 0.420 0.500 Balance 0.600 0.900 0.040 0.050
AISI 1045 (200 Bhn) 0.420 0.500 Balance 0.600 0.900 0.040 0.050
AISI 1050 (Any Treatment) 0.470 0.550 Balance 0.600 0.900 0.040 0.050
AISI 1053 0.510 0.550 Balance 0.750 0.040 0.050
AISI 1060 0.550 0.660 Balance 0.600 0.900 0.040 0.050
AISI 1070 0.650 0.750 Balance 0.750 0.040 0.050
AISI 1095 0.900 1.030 Balance 0.300 0.500 0.040 0.050
AISI 1118 0.140 0.200 Balance 1.300 1.600 0.040 0.080 0.130
AISI 15-B-32 0.310 0.360 Balance 1.100 1.400 0.040 0.050 0.150 0.350
AISI 4120 0.180 0.230 0.800 1.100 Balance 0.400 0.600 0.150 0.250 0.040 0.040 0.200 0.350
AISI 4130 0.280 0.330 0.800 1.100 Balance 0.400 0.600 0.150 0.250 0.035 0.040 0.150 0.300
AISI 4140 (198 Bhn) 0.380 0.430 0.800 1.100 Balance 0.750 1.000 0.150 0.250 0.035 0.040 0.150 0.300
AISI 4340 0.370 0.430 0.700 0.900 Balance 0.600 0.800 0.200 0.300 1.650 2.000 0.035 0.040 0.230
AISI 4340M Steel 0.370 0.430 0.700 0.900 Balance 0.600 0.800 0.200 0.300 1.650 2.000 0.035 0.040 0.230
AISI 50-B-35 0.330 0.380 0.500 Balance 0.880 0.035 0.040 0.230
AISI 5160 (Any Treatment) 0.560 0.640 0.800 Balance 0.880 0.035 0.040 0.230
AISI 52100 0.980 1.100 1.450 Balance 0.350 0.025 0.025 0.230
AISI 8617 Core Hardened (46HRc) 0.150 0.200 0.500 Balance 0.800 0.200 0.550 0.035 0.040 0.230
AISI 8617 Core Hardened (59HRc) 0.150 0.200 0.500 Balance 0.800 0.200 0.550 0.035 0.040 0.230
AISI 8617 Unhardened (78HRb) 0.150 0.200 0.500 Balance 0.800 0.200 0.550 0.035 0.040 0.230
AISI 8620 0.180 0.230 0.400 0.600 Balance 0.700 0.900 0.150 0.250 0.400 0.700 0.035 0.040 0.150 0.350
AISI 9310 0.100 1.200 Balance 0.550 0.120 3.330 0.010 0.010 0.250
ASTM B-688 Stainless Steel 0.030 20.000 22.000 0.750 Balance 2.000 6.000 7.000 23.500 25.500 0.040 0.030 1.000
Brico 3010 0.700 1.100 2.500 4.000 15.000 25.000 Balance 0.100 0.700 4.000 6.000 0.050 0.300 2.000 3.000 3.900 5.500
Carpenter Alloy A286 Stainless 0.035 0.006 0.080 13.500 16.000 0.250 Balance 2.000 24.000 27.000 0.040 0.030 1.000 2.125 0.100 0.500
CPM 9V 1.900 5.250 Balance 1.300 9.100
CrMoV Gun Barrel Steel 0.360 0.470 0.900 1.300 Balance 0.710 1.040 0.520 0.730 0.001 0.001 0.180 0.370 0.130 0.170
D2 Tool Steel 1.400 1.600 1.000 11.000 13.000 Balance 0.600 0.700 1.200 0.030 0.030 0.600 1.100
341

D3 1.500 12.000 Balance 0.600 0.800 0.030 0.030 0.400 0.350
D3 Tool Steel 2.000 2.350 11.000 13.000 Balance 0.600 0.030 0.030 0.600 1.100 1.000
Ferralium 255 Forged Stainless 0.040 26.000 1.700 Balance 0.800 3.300 0.170 5.500 0.450
H13 (Any Hardness) 0.320 0.400 5.130 5.250 Balance 1.330 1.400 1.000 1.000
HB3 0.380 5.020 Balance 0.330 1.350 0.120 0.940 0.120
HB7 0.380 5.020 Balance 0.330 1.350 0.120 0.940 0.120
Incoloy A286 0.350 0.001 0.010 0.080 13.500 16.000 Balance 2.000 1.000 1.500 24 27 0.030 1.900 2.350 0.100 0.500 3.000 4.500
Invar 0.020 Balance 0.35 0.200
Nitralloy 1.200 0.240 1.150 Balance 0.600 0.250 3.500 0.300
PH13-8Mo 0.900 1.350 0.050 12.250 13.250 Balance 0.100 2.000 2.500 0.010 7.500 8.500 0.010 0.008 0.100
SAE 5120 0.170 0.220 0.800 Balance 0.800 0.035 0.040 0.230
SAE 52100 0.950 1.500 Balance 0.350 0.250 0.025 0.002 0.250
SS2205 0.020 22.400 Balance 0.700 3.300 0.160 5.800 0.025 0.001 0.400
X53 0.100 1.000 2.000 Balance 0.350 3.250 2.000 1.000 0.100
Ta ble 1 9 .1 0 : M a t e r ia l Com posit ion : Tit a n iu m s

Al C Cr Cu Fe H Mn Mo N O Si Sn Ti V Zr
( D e sign a t ion
CP Ti Grade 2 0.100 0.300 0.015 0.030 0.250 Balance
CP Ti Grade 3 0.100 0.300 0.015 0.050 0.350 Balance
Ti 5Al-5V-5Mo-3Cr 5.000 3.000 0.500 5.000 Balance 5.000
Ti-10V-2Fe-3Al 3.000 2.000 Balance 10.000
Ti-4Al-4Mo-2Sn 4.000 4.000 0.500 2.000 Balance
Ti54M 5.000 0.400 0.800 Balance 4.000
Ti-5Al-2.5Sn ELI 5.000 0.250 0.120 2.500 Balance
Ti-5Al-2Sn-4Mo-2Zr-4Cr 5.000 4.000 4.000 2.000 Balance 2.000
Ti-6-2-4-2 6.000 2.000 0.080 2.000 Balance 4.000
Ti-6-2-4-6 6.000 6.000 2.000 Balance 4.000
Ti-6Al-2Fe-0.1Si 6.000 0.080 1.300 2.000 0.040 0.150 0.200 0.070 0.130 Balance
Ti-6Al-4V 6.000 0.200 0.300 0.200 Balance 4.000
Ti-6Al-4V ELI 6.000 0.140 0.130 Balance 4.000
Ti-6Al-6V-2Sn 6.000 2.000 Balance 6.000
Ta ble 1 9 .1 1 : M a t e r ia l Com posit ion : Ca st I r on s

C Cr Cu Fe Mn Mo Ni P S Si Sn
m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax
CGI-Ferritic 3.400 3.700 Balance 0.500 0.800 0.150 2.300 2.800 0.150
CGI-Pearlitic 3.400 3.700 Balance 0.500 0.800 0.150 2.300 2.800 0.150
D4512 3.600 3.800 0.030 0.070 0.150 1.000 Balance 0.150 1.000 0.010 0.100 0.050 0.200 0.030 0.002 1.800 2.800
D5506 3.200 4.100 Balance 0.100 1.000 0.015 0.100 0.005 0.035 1.800 3.000
GM8673 3.280 0.300 0.800 Balance 0.680 0.100 0.160 2.230
Nodular 4010 3.600 3.800 0.100 Balance 0.500 0.050 0.020
342
Ta ble 1 9 .1 1 : M a t e r ia l Com posit ion : Ca st I r on s

C Cr Cu Fe Mn Mo Ni P S Si Sn
m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax
SAEG1800 3.400 3.700 Balance 0.500 0.800 0.150 0.150 2.300 2.800
SAEG2500 3.200 3.500 Balance 0.600 0.900 0.120 0.150 2.000 2.400
SAEG3000 3.300 3.400 Balance 0.600 0.900 0.100 0.150 1.900 2.300
SAEG3500 3.000 3.300 Balance 0.600 0.900 0.080 0.150 1.800 2.200
SAEG4000 3.000 3.300 Balance 0.700 1.000 0.070 0.150 1.800 2.100
Ta ble 1 9 .1 2 : M a t e r ia l Com posit ion : Ot h e r

Al C Ca Ce Cu Fe Hf Mg Mn N Nb Ni Pb Sr Sn Si Ti V W Zn Zr Ra r e Ea r t h s
m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax m in m ax
AE44 3.980 Balance 0.350 0.200
C37700 Brass Balance 0.300 1.500 2.500 0.100 39.000
MRI153 9.000 1.000 Balance 0.700
MRI230 12.700 0.170 0.900 0.001 0.004 Balance 0.320 0.002 0.280 0.990 0.010 0.000
Nb C-103 10.000 Balance 1.000
Ni Al Bronze 9.000 Balance 4.000 5.000
Sonoston 4.210 0.020 37.450 2.860 54.0 Balance 0.060
Tungsten Balance
ZE41A 0.75 1.75 0.1 Balance 0.15 0.01 3.500 5.000 0.400 1.000
343
344
345
346
347
348

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3D External File Imports

Results Utilities: Tecplot

Suspicious Geometry Causes Bad Visualization....................................................... 306

• Reduced expensive cutting tests

• 2D Graphical User Interface (GUI)

• Standard cutting tool geometries with rake and clearance angles

• Process type options:

• Ever-increasing library of experimentally and numerically validated material models for

• Fully-automatic adaptive remeshing of finite element mesh, resolving features such as

VI SUALI ZATI ON OF RESULTS

Minimum System Requirements

• 2.5 GHz quad core Intel/AMD or higher processor

• 3.0 GHz quad core Intel Xeon/AMD or higher processor

• Single processor with multi-core configurations

Regional Settings (International Customers Only)

• Ctrl+N: New Project Window

• Ctrl+f: Fit to Full Size

1.1 — Start a New Project

1.2 — Identify the Process Type

• Feed is measured in distance/revolution

N ot e : The micro-machining feature should only be run by advanced AdvantEdge users.

• Feed is measured in distance/revolution/tooth

• Feed is measured in distance/tooth

• Feed is measured in distance/tooth

1.3 — 2D Graphical User Interface (GUI)

1.4 — Select Units

1.5 — Set Preferences

2.1 — Start a New Project

2.2 — Identify the Process Type

• O b l i q u e T u r n i n g — Turning simulated without consideration of tool nose radius. Equivalent

• Si d e Cu t t i n g — Peripheral milling, not taking into account end of cutter

• Co r n e r Cu t t i n g — End/ball end milling, taking into account end of cutter

M illin g Ope r a t ion 5 - Ax is Con st a n t

CON STAN T CH I P LOAD M I LLI N G

N ot e : Constant chip load milling is not recommended if temperatures need to be found,

• En t r a n ce p r o ce sse s simulate a drill entering a non-predrilled surface. In this model, the

2.3 — 3D Graphical User Interface (GUI)

Fi t — fits the tool/workpiece into the view

D y n a m i c P a n — pans by holding the left mouse button

Fr o n t V i e w — rotates tool/workpiece to front view

T o p V i e w — rotates tool/workpiece to top view

Le f t V i e w — rotates tool/workpiece to left view

Ba ck V i e w — rotates tool/workpiece to back view

R i g h t V i e w — rotates tool/workpiece to right view

Bo t t o m V i e w — rotates tool/workpiece to bottom view

I so V i e w — rotates tool/workpiece to isometric view

W i r e f r a m e — displays tool/workpiece in wireframe form

So l i d — displays tool/workpiece in solid form

Gr i d — turns grid on/off

Gr i d R e f i n e — sets the grid size

R e g e n e r a t e T o o l / W o r k p i e ce — updates the GUI view

2.4 — Select Units