Merge pull request #16021 from jbaehr/material-add-machining-wood-cards

Material: Add wood cards with machining model

src/Mod/Material/CMakeLists.txt

@@ -175,6 +175,7 @@ SET(AppearanceLib_Files
     Resources/Materials/Appearance/Silver.FCMat
     Resources/Materials/Appearance/Steel.FCMat
     Resources/Materials/Appearance/Stone.FCMat
+    Resources/Materials/Appearance/Wood.FCMat
 )
 
 SET(PatternLib_Files
@@ -216,10 +217,15 @@ SET(MachiningLib_Files
     Resources/Materials/Machining/AluminumCastAlloy.FCMat
     Resources/Materials/Machining/AluminumWroughtAlloy.FCMat
     Resources/Materials/Machining/AusteniticStainlessSteel.FCMat
+    Resources/Materials/Machining/BalsaWood.FCMat
     Resources/Materials/Machining/GrayCastIron.FCMat
+    Resources/Materials/Machining/HardWood.FCMat
     Resources/Materials/Machining/LowAlloySteel.FCMat
     Resources/Materials/Machining/MalleableCastIron.FCMat
     Resources/Materials/Machining/MildSteel.FCMat
+    Resources/Materials/Machining/MDF.FCMat
+    Resources/Materials/Machining/ParticleBoard.FCMat
+    Resources/Materials/Machining/SoftWood.FCMat
     Resources/Materials/Machining/ToolSteel.FCMat
 )
 

src/Mod/Material/Resources/Materials/Appearance/Wood.FCMat

@@ -0,0 +1,16 @@
+---
+General:
+  UUID: "1850ac4a-0df2-43cd-9934-e59e95b9526f"
+  Author: "Jonas Bähr"
+  License: "CC-BY-3.0"
+  Name: "Wood"
+  Description: "Defines generic Wood appearance properties"
+AppearanceModels:
+  BasicRendering:
+    UUID: 'f006c7e4-35b7-43d5-bbf9-c5d572309e6e'
+    AmbientColor: "(0.375, 0.1875, 0.0000, 1.0)"
+    DiffuseColor: "(0.8984, 0.7305, 0.3906, 1.0)"
+    EmissiveColor: "(0.0000, 0.0000, 0.0000, 1.0)"
+    Shininess: "0.9500"
+    SpecularColor: "(0.7461, 0.3750, 0.0000, 1.0)"
+    Transparency: "0.0"

src/Mod/Material/Resources/Materials/Machining/BalsaWood.FCMat

@@ -0,0 +1,51 @@
+General:
+  UUID: "93e4c9a8-7d9a-4ac2-88ea-77cd803f0514"
+  Author: "Jonas Bähr"
+  License: "CC-BY-3.0"
+  Name: "Balsa Wood"
+  Description: >-
+    Balsa Wood is very soft and of exceptionally low density.
+    Wood is highly anisotropic and here data is provided only for the single
+    cutting direction that is the toughest: the crosscut (direction A, as
+    defined by Kivimaa).
+    The surface speeds given here are conservative values and can be increased up
+    to 4x on capable machines with sufficiently large tools.
+    In addition, the numbers here use the cutting force model from B.Ettelt,
+    which is less accurate for smaller chip loads, but has the advantage of being
+    compatible with the model from O.Kienzle commonly used for metals.
+    Another source of uncertaintly is the unknown base rake angle.
+    Together with the natural inhomogenities of Wood the numbers given here can
+    only serve as an initial estimate.
+    Source: Zerspanung von Holz und Holzwerkstoffen, https://www.hanser-fachbuch.de/fachbuch/artikel/9783446477698
+Inherits:
+  Wood:
+    UUID: "1850ac4a-0df2-43cd-9934-e59e95b9526f"
+Models:
+  Father:
+    UUID: '9cdda8b6-b606-4778-8f13-3934d8668e67'
+    Father: "Wood"
+  MaterialStandard:
+    UUID: '1e2c0088-904a-4537-925f-64064c07d700'
+    KindOfMaterial: "Wood"
+  Machinability:
+    UUID: '9d81fcb2-bf81-48e3-bb57-d45ecf380096'
+    # ISBN 978-3-446-47769-8, 2. Edition 2023, P. 66
+    # for contour milling, a wide range from 10m/s to 40m/s (up to 120m/s for HSC)
+    # is provided, without differentiation on the cutting material or type of wood.
+    # Here we take the lower end, based on the assumption that mainly hobbyists will
+    # apply this information. Here, smaller tool diameters are common, thus higher surface
+    # speeds are not achievable.
+    SurfaceSpeedHSS: '600 m/min'
+    SurfaceSpeedCarbide: '600 m/min'
+    # ISBN 978-3-446-47769-8, 2. Edition 2023, P. 120 (again citing work from B.Ettelt, 1987)
+    # provided is the upper bound of the given range 4..9 for direction A
+    # (values for direction B are 6 and direction C 3)
+    # Unfortunately, it is unknown with which rake angle the values have been obtained.
+    # The choice of 20° is arbitrary and needs revision. It should prevent underestimation
+    # of the calculated cutting force when expecting a value normalized for 0°.
+    # i.e. 9 / (1 - 20/100) is 11.25
+    # NB: Ettelt's model uses 'N/mm^1.5' because it does not normalizes the chip thickness,
+    # however, the definition of FC's Machinability-model requires this normalization.
+    UnitCuttingForce: '11.25 N/mm^2'
+    # Ettelt's model uses the square root of the chip thickness, i.e. an 0.5 as exponent
+    ChipThicknessExponent: 0.50

src/Mod/Material/Resources/Materials/Machining/HardWood.FCMat

@@ -0,0 +1,52 @@
+General:
+  UUID: "ba2474ee-f62c-45f5-b388-823ea105847f"
+  Author: "Jonas Bähr"
+  License: "CC-BY-3.0"
+  Name: "Hard Wood"
+  Description: >-
+    Prototype for various hard woods, with densities around 0.75 g/cm^3 (beech, oak, ...).
+    Wood is highly anisotropic and here data is provided only for the single
+    cutting direction that is the toughest: the crosscut (direction A, as
+    defined by Kivimaa).
+    The surface speeds given here are conservative values and can be increased up
+    to 4x on capable machines with sufficiently large tools.
+    In addition, the numbers here use the cutting force model from B.Ettelt,
+    which is less accurate for smaller chip loads, but has the advantage of being
+    compatible with the model from O.Kienzle commonly used for metals.
+    Another source of uncertaintly is the unknown base rake angle.
+    Together with the natural inhomogenities of Wood the numbers given here can
+    only serve as an initial estimate.
+    Source: Zerspanung von Holz und Holzwerkstoffen, https://www.hanser-fachbuch.de/fachbuch/artikel/9783446477698
+Inherits:
+  Wood:
+    UUID: "1850ac4a-0df2-43cd-9934-e59e95b9526f"
+Models:
+  Father:
+    UUID: '9cdda8b6-b606-4778-8f13-3934d8668e67'
+    Father: "Wood"
+  MaterialStandard:
+    UUID: '1e2c0088-904a-4537-925f-64064c07d700'
+    KindOfMaterial: "Wood"
+  Machinability:
+    UUID: '9d81fcb2-bf81-48e3-bb57-d45ecf380096'
+    # ISBN 978-3-446-47769-8, 2. Edition 2023, P. 66
+    # for contour milling, a wide range from 10m/s to 40m/s (up to 120m/s for HSC)
+    # is provided, without differentiation on the cutting material or type of wood.
+    # Here we take the lower end, based on the assumption that mainly hobbyists will
+    # apply this information. Here, smaller tool diameters are common, thus higher surface
+    # speeds are not achievable.
+    SurfaceSpeedHSS: '600 m/min'
+    SurfaceSpeedCarbide: '600 m/min'
+    # ISBN 978-3-446-47769-8, 2. Edition 2023, P. 120 (again citing work from B.Ettelt, 1987)
+    # provided is the mean of the upper bounds of the ranges given for beech (26..40) and
+    # oak (22..44), for direction A. (values for direction B are 12 and 10; for direction C
+    # 7.5 and 7 respectively)
+    # Unfortunately, it is unknown with which rake angle the values have been obtained.
+    # The choice of 20° is arbitrary and needs revision. It should prevent underestimation
+    # of the calculated cutting force when expecting a value normalized for 0°.
+    # i.e. 42 / (1 - 20/100) is 52.5
+    # NB: Ettelt's model uses 'N/mm^1.5' because it does not normalizes the chip thickness,
+    # however, the definition of FC's Machinability-model requires this normalization.
+    UnitCuttingForce: '52.5 N/mm^2'
+    # Ettelt's model uses the square root of the chip thickness, i.e. an 0.5 as exponent
+    ChipThicknessExponent: 0.50

src/Mod/Material/Resources/Materials/Machining/MDF.FCMat

@@ -0,0 +1,47 @@
+General:
+  UUID: "be13eefa-72fc-477e-9b2f-b1ae8d1b551e"
+  Author: "Jonas Bähr"
+  License: "CC-BY-3.0"
+  Name: "Medium-Density Fibreboard (MDF)"
+  Description: >-
+    MDF is an engineered wood product, composed of wood fibers and a binding resin,
+    pressed together under high temperatures.
+    The surface speeds given here are conservative values and can be increased up
+    to 4x on capable machines with sufficiently large tools.
+    In addition, the numbers here use the cutting force model from B.Ettelt,
+    which is less accurate for smaller chip loads, but has the advantage of being
+    compatible with the model from O.Kienzle commonly used for metals.
+    Another source of uncertaintly is the unknown base rake angle.
+    Overall, the numbers given here can only serve as an initial estimate.
+    Source: Zerspanung von Holz und Holzwerkstoffen, https://www.hanser-fachbuch.de/fachbuch/artikel/9783446477698
+Inherits:
+  Wood:
+    UUID: "1850ac4a-0df2-43cd-9934-e59e95b9526f"
+Models:
+  Father:
+    UUID: '9cdda8b6-b606-4778-8f13-3934d8668e67'
+    Father: "Engineered Wood"
+  MaterialStandard:
+    UUID: '1e2c0088-904a-4537-925f-64064c07d700'
+    KindOfMaterial: "Wood"
+  Machinability:
+    UUID: '9d81fcb2-bf81-48e3-bb57-d45ecf380096'
+    # ISBN 978-3-446-47769-8, 2. Edition 2023, P. 66
+    # for contour milling, a wide range from 10m/s to 40m/s (up to 120m/s for HSC)
+    # is provided, without differentiation on the cutting material or type of wood.
+    # Here we take the lower end, based on the assumption that mainly hobbyists will
+    # apply this information. Here, smaller tool diameters are common, thus higher surface
+    # speeds are not achievable.
+    SurfaceSpeedHSS: '600 m/min'
+    SurfaceSpeedCarbide: '600 m/min'
+    # ISBN 978-3-446-47769-8, 2. Edition 2023, P. 120 (again citing work from B.Ettelt, 1987)
+    # provided is the upper bound of the given range 20..25.
+    # Unfortunately, it is unknown with which rake angle the values have been obtained.
+    # The choice of 20° is arbitrary and needs revision. It should prevent underestimation
+    # of the calculated cutting force when expecting a value normalized for 0°.
+    # i.e. 25 / (1 - 20/100) is 31.25
+    # NB: Ettelt's model uses 'N/mm^1.5' because it does not normalizes the chip thickness,
+    # however, the definition of FC's Machinability-model requires this normalization.
+    UnitCuttingForce: '31.25 N/mm^2'
+    # Ettelt's model uses the square root of the chip thickness, i.e. an 0.5 as exponent
+    ChipThicknessExponent: 0.50

src/Mod/Material/Resources/Materials/Machining/ParticleBoard.FCMat

@@ -0,0 +1,48 @@
+General:
+  UUID: "2f241065-8590-46c3-aa6e-02a999739d1a"
+  Author: "Jonas Bähr"
+  License: "CC-BY-3.0"
+  Name: "Particle Board"
+  Description: >-
+    Particle boards are engineered wood products, composed of wood chips pressed
+    together with a resin.
+    The surface speeds given here are conservative values and can be increased up
+    to 4x on capable machines with sufficiently large tools.
+    In addition, the numbers here use the cutting force model from B.Ettelt,
+    which is less accurate for smaller chip loads, but has the advantage of being
+    compatible with the model from O.Kienzle commonly used for metals.
+    Another source of uncertaintly is the unknown base rake angle.
+    Then, particle boards can differ significantly in density, chip size and type of
+    resin, so the numbers given here can only serve as an initial estimate.
+    Source: Zerspanung von Holz und Holzwerkstoffen, https://www.hanser-fachbuch.de/fachbuch/artikel/9783446477698
+Inherits:
+  Wood:
+    UUID: "1850ac4a-0df2-43cd-9934-e59e95b9526f"
+Models:
+  Father:
+    UUID: '9cdda8b6-b606-4778-8f13-3934d8668e67'
+    Father: "Engineered Wood"
+  MaterialStandard:
+    UUID: '1e2c0088-904a-4537-925f-64064c07d700'
+    KindOfMaterial: "Wood"
+  Machinability:
+    UUID: '9d81fcb2-bf81-48e3-bb57-d45ecf380096'
+    # ISBN 978-3-446-47769-8, 2. Edition 2023, P. 66
+    # for contour milling, a wide range from 10m/s to 40m/s (up to 120m/s for HSC)
+    # is provided, without differentiation on the cutting material or type of wood.
+    # Here we take the lower end, based on the assumption that mainly hobbyists will
+    # apply this information. Here, smaller tool diameters are common, thus higher surface
+    # speeds are not achievable.
+    SurfaceSpeedHSS: '600 m/min'
+    SurfaceSpeedCarbide: '600 m/min'
+    # ISBN 978-3-446-47769-8, 2. Edition 2023, P. 120 (again citing work from B.Ettelt, 1987)
+    # provided is the upper bound of the given range 12..18.
+    # Unfortunately, it is unknown with which rake angle the values have been obtained.
+    # The choice of 20° is arbitrary and needs revision. It should prevent underestimation
+    # of the calculated cutting force when expecting a value normalized for 0°.
+    # i.e. 18 / (1 - 20/100) is 22.5
+    # NB: Ettelt's model uses 'N/mm^1.5' because it does not normalizes the chip thickness,
+    # however, the definition of FC's Machinability-model requires this normalization.
+    UnitCuttingForce: '22.5 N/mm^2'
+    # Ettelt's model uses the square root of the chip thickness, i.e. an 0.5 as exponent
+    ChipThicknessExponent: 0.50

src/Mod/Material/Resources/Materials/Machining/SoftWood.FCMat

@@ -0,0 +1,52 @@
+General:
+  UUID: "e075e464-2b13-474f-bcf7-d0651297d364"
+  Author: "Jonas Bähr"
+  License: "CC-BY-3.0"
+  Name: "Soft Wood"
+  Description: >-
+    Prototype for various soft woods, with densities around 0.5 g/cm^3 (pine, spruce, ...).
+    Wood is highly anisotropic and here data is provided only for the single
+    cutting direction that is the toughest: the crosscut (direction A, as
+    defined by Kivimaa).
+    The surface speeds given here are conservative values and can be increased up
+    to 4x on capable machines with sufficiently large tools.
+    In addition, the numbers here use the cutting force model from B.Ettelt,
+    which is less accurate for smaller chip loads, but has the advantage of being
+    compatible with the model from O.Kienzle commonly used for metals.
+    Another source of uncertaintly is the unknown base rake angle.
+    Together with the natural inhomogenities of Wood the numbers given here can
+    only serve as an initial estimate.
+    Source: Zerspanung von Holz und Holzwerkstoffen, https://www.hanser-fachbuch.de/fachbuch/artikel/9783446477698
+Inherits:
+  Wood:
+    UUID: "1850ac4a-0df2-43cd-9934-e59e95b9526f"
+Models:
+  Father:
+    UUID: '9cdda8b6-b606-4778-8f13-3934d8668e67'
+    Father: "Wood"
+  MaterialStandard:
+    UUID: '1e2c0088-904a-4537-925f-64064c07d700'
+    KindOfMaterial: "Wood"
+  Machinability:
+    UUID: '9d81fcb2-bf81-48e3-bb57-d45ecf380096'
+    # ISBN 978-3-446-47769-8, 2. Edition 2023, P. 66
+    # for contour milling, a wide range from 10m/s to 40m/s (up to 120m/s for HSC)
+    # is provided, without differentiation on the cutting material or type of wood.
+    # Here we take the lower end, based on the assumption that mainly hobbyists will
+    # apply this information. Here, smaller tool diameters are common, thus higher surface
+    # speeds are not achievable.
+    SurfaceSpeedHSS: '600 m/min'
+    SurfaceSpeedCarbide: '600 m/min'
+    # ISBN 978-3-446-47769-8, 2. Edition 2023, P. 120 (again citing work from B.Ettelt, 1987)
+    # provided is the mean of the upper bounds of the ranges given for pine (14..31) and
+    # spruce (15..28), for direction A. (values for direction B are 7,5 and 9; for direction C
+    # 5 and 6 respectively)
+    # Unfortunately, it is unknown with which rake angle the values have been obtained.
+    # The choice of 20° is arbitrary and needs revision. It should prevent underestimation
+    # of the calculated cutting force when expecting a value normalized for 0°.
+    # i.e. 29.5 / (1 - 20/100) is 36.875
+    # NB: Ettelt's model uses 'N/mm^1.5' because it does not normalizes the chip thickness,
+    # however, the definition of FC's Machinability-model requires this normalization.
+    UnitCuttingForce: '36.9 N/mm^2'
+    # Ettelt's model uses the square root of the chip thickness, i.e. an 0.5 as exponent
+    ChipThicknessExponent: 0.50

src/Mod/Material/Resources/Materials/Standard/Wood/Wood-Generic.FCMat

@@ -6,6 +6,9 @@ General:
   License: "CC-BY-3.0"
   Name: "Wood"
   Description: "A standard construction wood"
+Inherits:
+  Wood:
+    UUID: "1850ac4a-0df2-43cd-9934-e59e95b9526f"
 Models:
   Father:
     UUID: '9cdda8b6-b606-4778-8f13-3934d8668e67'