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Material: Add metal cards with machining model

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With PR #14460 the "machinability" model was introduced. As sample data
the legacy material cards from the "feeds and speeds" addon were added
and (partly) converted to the new format. However, due to copyright
concerns and unclear semantics of the data, the values required for
cutting force calculations have been removed.
This commits adds material cards with complete machining model data
for various classes of metals. The data comes from the German standard
work "Tabellenbuch Zerspantechnik", ISBN 978-3-7585-1315-2, 5. Edition
2022, http://www.europa-lehrmittel.de/14733
Usage of this data for our purpose is legal as facts are not protected by
copyright according to German law. This view has been confirmed by the
licensing department of the publisher.
This commit is contained in:
Jonas Bähr
2024-08-17 10:00:31 +02:00
committed by sliptonic
parent 8dc1fad1c9
commit 95c514fca3
9 changed files with 304 additions and 13 deletions
Download Patch File Download Diff File Expand all files Collapse all files

7
src/Mod/Material/CMakeLists.txt
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@@ -216,12 +216,19 @@ SET(MachiningLib_Files
Resources/Materials/Machining/Aluminum-6061.FCMat
Resources/Materials/Machining/Aluminum-7075.FCMat
Resources/Materials/Machining/Aluminum-Cast.FCMat
Resources/Materials/Machining/AluminumCastAlloy.FCMat
Resources/Materials/Machining/AluminumWroughtAlloy.FCMat
Resources/Materials/Machining/AusteniticStainlessSteel.FCMat
Resources/Materials/Machining/Brass-Hard.FCMat
Resources/Materials/Machining/Brass-Medium.FCMat
Resources/Materials/Machining/Brass-Soft.FCMat
Resources/Materials/Machining/CarbonSteel.FCMat
Resources/Materials/Machining/GrayCastIron.FCMat
Resources/Materials/Machining/HardPlastics.FCMat
Resources/Materials/Machining/Hardwood.FCMat
Resources/Materials/Machining/LowAlloySteel.FCMat
Resources/Materials/Machining/MalleableCastIron.FCMat
Resources/Materials/Machining/MildSteel.FCMat
Resources/Materials/Machining/SoftPlastics.FCMat
Resources/Materials/Machining/Softwood.FCMat
Resources/Materials/Machining/Stainless-303.FCMat

37
src/Mod/Material/Resources/Materials/Machining/AluminumCastAlloy.FCMat Normal file
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General:
UUID: '048ba0ec-1fc4-4e3c-9710-bde305a1503f'
Author: "Jonas Bähr"
License: "CC-BY-3.0"
Name: "Aluminum (Hard Cast Alloy)"
Description: >-
Prototype for various high-silicon cast aluminium alloys.
Surface speeds given for uncoated bits; coated bits can operate 50% to 70% faster.
Surface speeds given for roughing with a width of cut less than half the bit's diameter.
For finishing with woc <= 0.1 * D carbide bits can operatre 2.5 times faster.
For slotting with woc <= D HSS bits should operate 25% slower.
NB: Specific alloys can deviate significantly!
Source: Tabellenbuch Zerspantechnik, http://www.europa-lehrmittel.de/14733
Inherits:
Aluminum:
UUID: "d1f317f0-5ffa-4798-8ab3-af2ff0b5182c"
Models:
Father:
UUID: '9cdda8b6-b606-4778-8f13-3934d8668e67'
Father: "Metal"
MaterialStandard:
UUID: '1e2c0088-904a-4537-925f-64064c07d700'
KindOfMaterial: "Aluminium"
Machinability:
UUID: '9d81fcb2-bf81-48e3-bb57-d45ecf380096'
# ISBN 978-3-7585-1315-2, 5. Edition 2022, P. 272
# uncoated HSS, contour milling, roughing (woc: < 0.5 D, doc: < 1.5 D)
SurfaceSpeedHSS: '80 m/min'
# ISBN 978-3-7585-1315-2, 5. Edition 2022, P. 274
# uncoated carbide, contour milling, roughing (woc: < 0.5 D, doc: < 1.5 D)
SurfaceSpeedCarbide: '120 m/min'
# ISBN 978-3-7585-1315-2, 5. Edition 2022, P. 215
# Chip compression correction for milling, 1.2, already applied,
# base rake angle transformed from gamma_0=12° (aluminium, cf. P. 216) to 0°
# i.e. 680 * 1.2 / (1 - 12/100) is 927.273
UnitCuttingForce: '927 N/mm^2'
ChipThicknessExponent: 0.27

38
src/Mod/Material/Resources/Materials/Machining/AluminumWroughtAlloy.FCMat Normal file
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General:
UUID: "5528dd01-e009-4e88-8c71-d5e9bbe8f7f3"
Author: "Jonas Bähr"
License: "CC-BY-3.0"
Name: "Aluminum (Soft Wrought Alloy)"
Description: >-
Prototype for various easy-to-machine wrought aluminium alloys.
Surface speeds given for uncoated bits; coated bits can operate 50% faster.
Surface speeds given for roughing with a width of cut less than half the bit's diameter.
The same values can be used for slotting (woc <= D).
For finishing with woc <= 0.1 * D carbide bits can operatre 2.2 times faster.
NB: Specific alloys can deviate significantly!
Source: Tabellenbuch Zerspantechnik, http://www.europa-lehrmittel.de/14733
Inherits:
Aluminum:
UUID: "d1f317f0-5ffa-4798-8ab3-af2ff0b5182c"
Models:
Father:
UUID: '9cdda8b6-b606-4778-8f13-3934d8668e67'
Father: "Metal"
MaterialStandard:
UUID: '1e2c0088-904a-4537-925f-64064c07d700'
KindOfMaterial: "Aluminium"
Machinability:
UUID: '9d81fcb2-bf81-48e3-bb57-d45ecf380096'
# ISBN 978-3-7585-1315-2, 5. Edition 2022, P. 272
# uncoated HSS, contour milling, roughing (woc: < 0.5 D, doc: < 1.5 D)
SurfaceSpeedHSS: '120 m/min'
# ISBN 978-3-7585-1315-2, 5. Edition 2022, P. 274
# uncoated carbide, contour milling, roughing (woc: < 0.5 D, doc: < 1.5 D)
# under "favorable condition" 50% higher: 180 * 150% = 270
SurfaceSpeedCarbide: '270 m/min'
# ISBN 978-3-7585-1315-2, 5. Edition 2022, P. 215
# Chip compression correction for milling, 1.2, already applied,
# base rake angle transformed from gamma_0=12° (aluminium, cf. P. 216) to 0°
# i.e. 470 * 1.2 / (1 - 12/100) is 641.909
UnitCuttingForce: '641 N/mm^2'
ChipThicknessExponent: 0.27

37
src/Mod/Material/Resources/Materials/Machining/AusteniticStainlessSteel.FCMat Normal file
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General:
UUID: "5857838c-56e3-493e-9d89-5896718f0a15"
Author: "Jonas Bähr"
License: "CC-BY-3.0"
Name: "Austenitic Stainless Steel"
Description: >-
Prototype for austenitic stainless steels.
Surface speeds given for uncoated bits; coated bits can operate 65% to 85% faster.
Surface speeds given for roughing with a width of cut less than half the bit's diameter.
The same values can be used for slotting (woc <= D).
For finishing with woc <= 0.1 * D surface speeds can be increased by 30% to 50%.
NB: Specific alloys can deviate significantly!
Source: Tabellenbuch Zerspantechnik, http://www.europa-lehrmittel.de/14733
Inherits:
Steel:
UUID: "4b849c55-6b3a-4f75-a055-40c0d0324596"
Models:
Father:
UUID: '9cdda8b6-b606-4778-8f13-3934d8668e67'
Father: "Metal"
MaterialStandard:
UUID: '1e2c0088-904a-4537-925f-64064c07d700'
KindOfMaterial: "Steel"
Machinability:
UUID: '9d81fcb2-bf81-48e3-bb57-d45ecf380096'
# ISBN 978-3-7585-1315-2, 5. Edition 2022, P. 272
# uncoated HSS, contour milling, roughing (woc: < 0.5 D, doc: < 1.5 D)
SurfaceSpeedHSS: '12 m/min'
# ISBN 978-3-7585-1315-2, 5. Edition 2022, P. 274
# uncoated carbide, contour milling, roughing (woc: < 0.5 D, doc: < 1.5 D)
SurfaceSpeedCarbide: '45 m/min'
# ISBN 978-3-7585-1315-2, 5. Edition 2022, P. 215
# Chip compression correction for milling, 1.2, already applied,
# base rake angle transformed from gamma_0=6° (steel, cf. P. 216) to 0°
# i.e. 2000 * 1.2 / (1 - 6/100) is 2553.191
UnitCuttingForce: '2553 N/mm^2'
ChipThicknessExponent: 0.20

37
src/Mod/Material/Resources/Materials/Machining/GrayCastIron.FCMat Normal file
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General:
UUID: "73b598d1-fa8a-4245-a87f-9f333abfe39c"
Author: "Jonas Bähr"
License: "CC-BY-3.0"
Name: "Gray Cast Iron"
Description: >-
Prototype for gray cast iron, GJL.
Surface speeds given for uncoated bits; coated bits can operate 2 times faster.
Surface speeds given for roughing with a width of cut less than half the bit's diameter.
The same values can be used for slotting (woc = D).
For finishing with woc <= 0.1 * D carbide bits can operatre 30% faster.
NB: Specific alloys can deviate significantly!
Source: Tabellenbuch Zerspantechnik, http://www.europa-lehrmittel.de/14733
Inherits:
Steel:
UUID: "4b849c55-6b3a-4f75-a055-40c0d0324596"
Models:
Father:
UUID: '9cdda8b6-b606-4778-8f13-3934d8668e67'
Father: "Metal"
MaterialStandard:
UUID: '1e2c0088-904a-4537-925f-64064c07d700'
KindOfMaterial: "Cast Iron"
Machinability:
UUID: '9d81fcb2-bf81-48e3-bb57-d45ecf380096'
# ISBN 978-3-7585-1315-2, 5. Edition 2022, P. 272
# uncoated HSS, contour milling, roughing (woc: < 0.5 D, doc: < 1.5 D)
SurfaceSpeedHSS: '25 m/min'
# ISBN 978-3-7585-1315-2, 5. Edition 2022, P. 274
# uncoated carbide, contour milling, roughing (woc: < 0.5 D, doc: < 1.5 D)
SurfaceSpeedCarbide: '60 m/min'
# ISBN 978-3-7585-1315-2, 5. Edition 2022, P. 215
# Chip compression correction for milling, 1.2, already applied,
# base rake angle transformed from gamma_0=2° (cast iron, cf. P. 216) to 0°
# i.e. 1050 * 1.2 / (1 - 2/100) is 1285.714
UnitCuttingForce: '1286 N/mm^2'
ChipThicknessExponent: 0.23

37
src/Mod/Material/Resources/Materials/Machining/LowAlloySteel.FCMat Normal file
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General:
UUID: "eb695e3f-4d45-4935-9f40-c4dd8966f0a8"
Author: "Jonas Bähr"
License: "CC-BY-3.0"
Name: "Low Alloy Steel"
Description: >-
Prototype for low alloy steels.
Surface speeds given for uncoated bits; coated bits can operate 1.5 to 2.5 times faster.
Surface speeds given for roughing with a width of cut less than half the bit's diameter.
For finishing with woc <= 0.1 * D carbide bits can operatre 20% to 40% faster.
For slotting with woc <= D carbide bits should operate 10% to 25% slower.
NB: Specific alloys can deviate significantly!
Source: Tabellenbuch Zerspantechnik, http://www.europa-lehrmittel.de/14733
Inherits:
Steel:
UUID: "4b849c55-6b3a-4f75-a055-40c0d0324596"
Models:
Father:
UUID: '9cdda8b6-b606-4778-8f13-3934d8668e67'
Father: "Metal"
MaterialStandard:
UUID: '1e2c0088-904a-4537-925f-64064c07d700'
KindOfMaterial: "Steel"
Machinability:
UUID: '9d81fcb2-bf81-48e3-bb57-d45ecf380096'
# ISBN 978-3-7585-1315-2, 5. Edition 2022, P. 272
# uncoated HSS, contour milling, roughing (woc: < 0.5 D, doc: < 1.5 D)
SurfaceSpeedHSS: '20 m/min'
# ISBN 978-3-7585-1315-2, 5. Edition 2022, P. 274
# uncoated carbide, contour milling, roughing (woc: < 0.5 D, doc: < 1.5 D)
SurfaceSpeedCarbide: '60 m/min'
# ISBN 978-3-7585-1315-2, 5. Edition 2022, P. 215
# Chip compression correction for milling, 1.2, already applied,
# base rake angle transformed from gamma_0=6° (steel, cf. P. 216) to 0°
# i.e. 2200 * 1.2 / (1 - 6/100) is 2808.511
UnitCuttingForce: '2809 N/mm^2'
ChipThicknessExponent: 0.24

37
src/Mod/Material/Resources/Materials/Machining/MalleableCastIron.FCMat Normal file
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General:
UUID: "b5c9fff8-0a37-4a62-b633-81a737744d19"
Author: "Jonas Bähr"
License: "CC-BY-3.0"
Name: "Malleable Cast Iron"
Description: >-
Prototype for malleable cast iron, GJM.
Surface speeds given for uncoated bits; coated bits can operate 60% to 70% faster.
Surface speeds given for roughing with a width of cut less than half the bit's diameter.
The same values can be used for slotting (woc <= D)
For finishing with woc <= 0.1 * D bits can operatre 10% to 20% faster.
NB: Specific alloys can deviate significantly!
Source: Tabellenbuch Zerspantechnik, http://www.europa-lehrmittel.de/14733
Inherits:
Steel:
UUID: "4b849c55-6b3a-4f75-a055-40c0d0324596"
Models:
Father:
UUID: '9cdda8b6-b606-4778-8f13-3934d8668e67'
Father: "Metal"
MaterialStandard:
UUID: '1e2c0088-904a-4537-925f-64064c07d700'
KindOfMaterial: "Cast Iron"
Machinability:
UUID: '9d81fcb2-bf81-48e3-bb57-d45ecf380096'
# ISBN 978-3-7585-1315-2, 5. Edition 2022, P. 272
# uncoated HSS, contour milling, roughing (woc: < 0.5 D, doc: < 1.5 D)
SurfaceSpeedHSS: '18 m/min'
# ISBN 978-3-7585-1315-2, 5. Edition 2022, P. 274
# uncoated carbide, contour milling, roughing (woc: < 0.5 D, doc: < 1.5 D)
SurfaceSpeedCarbide: '50 m/min'
# ISBN 978-3-7585-1315-2, 5. Edition 2022, P. 215
# Chip compression correction for milling, 1.2, already applied,
# base rake angle transformed from gamma_0=2° (cast iron, cf. P. 216) to 0°
# i.e. 1500 * 1.2 / (1 - 2/100) is 1836.735
UnitCuttingForce: '1837 N/mm^2'
ChipThicknessExponent: 0.28

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src/Mod/Material/Resources/Materials/Machining/MildSteel.FCMat Normal file
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General:
UUID: "029b8fac-d453-4ff5-ba26-b37a79a33d97"
Author: "Jonas Bähr"
License: "CC-BY-3.0"
Name: "Mild Steel"
Description: >-
Prototype for soft unalloyed steels with low carbon content.
Surface speeds given for uncoated bits; coated bits can operate 70% to 260% faster.
Surface speeds given for roughing with a width of cut less than half the bit's diameter.
For finishing with woc <= 0.1 * D bits can operatre 20% to 40% faster.
For slotting with woc <= D carbide bits should operate 15% slower.
NB: Specific alloys can deviate significantly!
Source: Tabellenbuch Zerspantechnik, http://www.europa-lehrmittel.de/14733
Inherits:
Steel:
UUID: "4b849c55-6b3a-4f75-a055-40c0d0324596"
Models:
Father:
UUID: '9cdda8b6-b606-4778-8f13-3934d8668e67'
Father: "Metal"
MaterialStandard:
UUID: '1e2c0088-904a-4537-925f-64064c07d700'
KindOfMaterial: "Steel"
Machinability:
UUID: '9d81fcb2-bf81-48e3-bb57-d45ecf380096'
# ISBN 978-3-7585-1315-2, 5. Edition 2022, P. 272
# uncoated HSS, contour milling, roughing (woc: < 0.5 D, doc: < 1.5 D)
SurfaceSpeedHSS: '25 m/min'
# ISBN 978-3-7585-1315-2, 5. Edition 2022, P. 274
# uncoated carbide, contour milling, roughing (woc: < 0.5 D, doc: < 1.5 D)
SurfaceSpeedCarbide: '70 m/min'
# ISBN 978-3-7585-1315-2, 5. Edition 2022, P. 215
# Chip compression correction for milling, 1.2, already applied,
# base rake angle transformed from gamma_0=6° (steel, cf. P. 216) to 0°
# i.e. 1800 * 1.2 / (1 - 6/100) is 2297.872
UnitCuttingForce: '2298 N/mm^2'
ChipThicknessExponent: 0.20

50
src/Mod/Material/Resources/Materials/Machining/ToolSteel.FCMat
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@@ -1,13 +1,37 @@
; Stainless(316)
; (c) 2022 Daniel Wood (CC-BY 3.0)
; information about the content of such cards can be found on the wiki:
; https://www.freecadweb.org/wiki/Material
[FCMat]
Name = Tool Steel
Description = Path Material ToolSteel
Father = Metal
SurfaceSpeed_HSS = 12
SurfaceSpeed_Carbide = 45
Kp = 1.88
Kd = 340000
General:
UUID: "32a4d8c1-89a5-4ca8-8d84-d3b6f5468880"
Author: "Jonas Bähr"
License: "CC-BY-3.0"
Name: "Tool Steel (unhardened)"
Description: >-
Prototype for normal, unhardened, cold working, tool steels.
Surface speeds given for uncoated bits; coated HSS bits can operate 2.3 times faster, carbite 30% faster.
Surface speeds given for roughing with a width of cut less than half the bit's diameter.
For finishing with woc <= 0.1 * D bits can operatre 30% to 50% faster.
For slotting with woc <= D carbite bits should operate 15% slower.
NB: Specific alloys can deviate significantly!
Source: Tabellenbuch Zerspantechnik, http://www.europa-lehrmittel.de/14733
Inherits:
Steel:
UUID: "4b849c55-6b3a-4f75-a055-40c0d0324596"
Models:
Father:
UUID: '9cdda8b6-b606-4778-8f13-3934d8668e67'
Father: "Metal"
MaterialStandard:
UUID: '1e2c0088-904a-4537-925f-64064c07d700'
KindOfMaterial: "Steel"
Machinability:
UUID: '9d81fcb2-bf81-48e3-bb57-d45ecf380096'
# ISBN 978-3-7585-1315-2, 5. Edition 2022, P. 272
# uncoated HSS, contour milling, roughing (woc: < 0.5 D, doc: < 1.5 D)
SurfaceSpeedHSS: '15 m/min'
# ISBN 978-3-7585-1315-2, 5. Edition 2022, P. 274
# uncoated carbide, contour milling, roughing (woc: < 0.5 D, doc: < 1.5 D)
SurfaceSpeedCarbide: '40 m/min'
# ISBN 978-3-7585-1315-2, 5. Edition 2022, P. 215
# Chip compression correction for milling, 1.2, already applied,
# base rake angle transformed from gamma_0=6° (steel, cf. P. 216) to 0°
# i.e. 2500 * 1.2 / (1 - 6/100) is 3191.489
UnitCuttingForce: '3191 N/mm^2'
ChipThicknessExponent: 0.27