Apparatus and method for simulating machining and other forming operations

Abstract

A method includes obtaining information associated with a forming operation involving a manufacturing machine having a tool that contacts material and simulating deformation of the material based on the information. Simulating the deformation of the material includes evaluating combinations of shear planes within an initial structure of the material. Simulating the deformation of the material also includes predicting a mode of deformation comprising one or more of the shear planes along which the initial structure of the material will likely deform. Simulating the deformation of the material further includes calculating a deformed shape of the material after an increment of deformation along the predicted mode of deformation. In addition, simulating the deformation of the material includes repeating the evaluating, predicting, and calculating with the deformed shape of the material as the initial structure one or more times to identify how one or more pieces of the material are removed by the tool during the forming operation over time.