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Material: Add wood cards with machining model

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With PR FreeCAD#14460 the "machinability" model was introduced.
This commits adds material cards with complete machining model data
for various types of woods and engineed wood products.
The data comes from the German text book "Zerspanung von Holz und
Holzwerkstoffen", ISBN 978-3-446-47769-8, 2. Edition 2023,
https://www.hanser-fachbuch.de/fachbuch/artikel/9783446477698
Usage of this data for our purpose is legal as facts are not protected by
copyright according to German law.
This commit is contained in:
Jonas Bähr
2024-08-23 18:40:00 +02:00
parent ae94393abd
commit a18a0b1cbf
6 changed files with 255 additions and 0 deletions
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5
src/Mod/Material/CMakeLists.txt
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@@ -217,10 +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
)

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

52
src/Mod/Material/Resources/Materials/Machining/HardWood.FCMat Normal file
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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

47
src/Mod/Material/Resources/Materials/Machining/MDF.FCMat Normal file
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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

48
src/Mod/Material/Resources/Materials/Machining/ParticleBoard.FCMat Normal file
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@@ -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

52
src/Mod/Material/Resources/Materials/Machining/SoftWood.FCMat Normal file
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@@ -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