DEFORM-3D is a robust simulation tool that uses the finite element method (FEM) to model complex machining processes in three dimensions. One of the most recent processes that has been modeled in DEFORM is drilling. The program has many features that can be daunting and difficult to adjust for a new user. These features combine machining and the FE model to simulate drilling operations. Although this program can generate useful results, it can be very difficult to obtain these results consistently. This is because the code is often subject to crashing when the simulation parameters are not set properly. By recognizing the common errors and idiosyncrasies of DEFORM, a user can generate useful simulations quickly and efficiently. The background, application, troubleshooting, and analysis of DEFORM-3D are presented to showcase its capabilities while discussing its limitations in drilling.

The choice of finite element software for machining analysis is an important factor in determining the quality and scope of analysis that can be performed. In this report, a comparative study is presented on three commercially available finite element analysis software packages detailing their applicability for performing machining simulations, specifically to study burr formation. The three packages presented are Deform, AdvantEdge and Abaqus. Each software package is discussed first and its advantages and disadvantages are presented. Then, the packages are compared and the suitable package for different scenarios is suggested.

The quality of machined components in the aerospace and automotive industries has become increasingly critical in the past years because of greater complexity of the workpieces, miniaturization, usage of new composite materials, and tighter tolerances. This trend has put continual pressure not only on improvements in machining operations, but also on the optimization of the cleanability of parts. The paper reviews recent work done in these areas at the University of California-Berkeley. This includes: Finite element modeling of burr formation in stacked drilling; development of drill geometries for burr minimization in curved-surface drilling; development of a enhanced drilling burr control chart; study of tool path planning in face-milling; and cleanability of components and cleanliness metrics.