Application examples
A selection of potential applications of Toolyzer for the design and optimization of tools and processes.
Circular milling – the right pitch
- Increased productivity: Determination of the maximum possible collision-free helix pitch
- Fast simulation setup thanks to integrated tool path generators
- Added value for users: Provide pitches depending on the bore diameter
Adequately dimension clamping systems
- Calculation of the process-related torques
- Moments can be calculated at any location and at any process time
- Cost savings through correct dimensioning
Optimizing tool geometry – influence of tooth pitch
- Knowledge of the influence of the positioning of the inserts
- Any complex tool geometries can be simulated
- Determination of optimum configurations with regard to torque and bending moment
Thread milling – Choosing the right feed rate
- Determination of the maximum chip thickness as a function of the feed rate and thread size
- For each individual cutting edge, local analysis incl. run-out error
- Prevention of premature tool wear
Ramping – determine ramp angle depending on strategy
- Easily determine possible ramp angles using collision analysis
- Optimization of the tool face geometry for maximum productivity
- Knowledge of differences between zig and zig-zag strategy
Multi-tool and multi-process analysis
- Simulation of any tools and processes within a simulation
- Simple adjustment of roughing and finishing tools, e.g. step drills, gear skiving tools
- Optimization across processes
Special tools – Simulation of large tools
- Fast analysis of different configurations, even of large special tools
- Early detection of potential design faults
- Simple torque prediction, identification of unequal loads on the inserts
Optimizing forming tools – example of fir tree tools
- Analyze and optimize any cutting edge profile
- Improvement of tool engagement, increase in tool life
- For processes and tools of any complexity
Improving special processes – example of polygon turning
- Implementation of special processes using the supplied programming interface
- Load analysis, detection of dimensional deviations due to faulty tool geometry or process control
- E.g. polygon turning, bevel gear milling and much more
Automate simulations – use of programming interface
- Simplified analysis of many tool and process configurations to find the optimum
- Automate evaluation and documentation
- Formulation of own parameters and criteria
Gear hobbing – optimization of process and tool
- Optimization of each individual hub to shorten the processing time
- Analysis of the resulting rake and clearance angle or chip thickness on the tool
- Avoiding collisions of the tool body
- Early detection of surface defects by analyzing the final workpiece geometry
Skiving – improving productivity and process reliability
- Optimization of each individual hub to shorten the processing time
- Identification of wear-critical areas on the tool
- Avoiding collisions of the tool body
- Early detection of dimensional deviations
Predict workpiece quality
- Checking geometric tolerances through integrated nominal/actual comparison
- Effects of feed rate, run-out errors, tilt errors, vibrations and more can be modeled
- Export of the machined workpiece as a point cloud or high-resolution STL file possible at any time
Whirling – Simple tool and process optimization
- Integrated generator for whirling processes
- Determination of the best possible process parameters for maximum productivity, taking into account the tool load
- Analysis of the workpiece geometry
Simulate torsional vibrations
- Detection of critical speeds, e.g. for drilling processes, by modeling torsional vibrations
- Own modeling possible via programming interface