Simulator Library
Manufacturing Process Simulators
Manufacturing simulators for machining, casting, welding, forming, additive manufacturing, and surface processing.
49 simulators
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Simulator list
SLM Laser Melt Pool Design Simulator
Design the laser melt pool — the core of metal SLM (powder-bed fusion) 3D printing — in real time. Adjust laser power, scan speed, hatch spacing and layer thickness, and…
AM Thermal Distortion & Residual Stress Simulator (Inherent Strain Method)
Estimate the warp and residual stress of metal AM parts (LPBF, EBM, DED) using the Inherent Strain method.
Additive Manufacturing & 3D Printing Thermal Calculator
Calculate FDM, SLA, SLS, DMLS build time, energy, cooling & warping risk. Supports PLA, ABS, 316L, Ti-6Al-4V. Real-time thermal analysis for 3D printing.
Blast Furnace Coke Rate & Reductant Ratio Simulator
A tool for designing the mass balance of a blast furnace.
Broaching Force Simulator
Compute the pull force and cutting power of a multi-tooth broach in real time. Change the cut width, rise per tooth, specific cutting force, number of teeth engaged and …
Carbon Equivalent Weldability Simulator
Enter the steel chemistry (C, Mn, Cr+Mo+V, Ni+Cu, Si) and the tool computes the international IIW carbon equivalent CE_IIW and the Ito-Bessyo Pcm cracking parameter, the…
Casting Riser Design Simulator
Casting & Forming
Size a sand-casting riser (feeder) so it stays liquid longer than the casting and feeds solidification shrinkage. Built on Chvorinov's rule t_s = K·M² and the Caine crit…
Casting Solidification Chvorinov Simulator
Casting & Forming
Casting Solidification Chvorinov Simulator updates live numeric results and charts as inputs change, supporting early design checks and model review.
Semiconductor CMP Removal Rate (Preston Equation) Simulator
Design a Chemical Mechanical Planarization (CMP) process for semiconductor wafers using Preston's equation RR = K_p·P·v. Adjust pad pressure, relative velocity and the m…
Semiconductor CMP Wafer Pad Pressure Uniformity Simulator
Evaluate chemical-mechanical planarization (CMP) recipes for 200/300/450mm wafers with the Preston equation.
CNC Machining
Calculate cutting force, tool life, MRR, and more with this free CNC machining calculator. Includes material data for aluminum, steel, and stainless steel.
CNC Milling Regenerative Chatter Stability Lobe Diagram Simulator
Solve the stability limit of regenerative chatter in end-mill machining using the Tlusty/Altintas analytical model. Adjust spindle speed, tooth count, tool natural frequ…
Cutting Temperature Estimator
An energy-balance tool that estimates the average cutting temperature at the tool tip during turning and milling.
Deep Drawing Force Simulator
Casting & Forming
Study the deep-drawing process that forms a flat sheet-metal blank into a cylindrical cup.
Eccentric Weld Group Simulator
Welding
Analyse what happens to a bracket connection made with two fillet welds when the load is applied off the centroid of the weld group — an eccentricity.
EDM Material Removal Rate Simulator
Adjust the discharge settings of die-sinking electrical discharge machining (EDM) and see how fast the process removes metal.
Fillet Weld Joint Strength Calculator
Welding
Calculate fillet weld strength per AWS, ISO, JIS standards. Input geometry & load to get throat thickness, shear/normal/resultant stresses, and safety factor.
Food Pasteurization D-value & F-value Simulator
Design pasteurization and sterilization processes for cans, milk and juice.
Forging Load Estimate Simulator
Casting & Forming
Estimate the press load needed for upsetting — squeezing a cylindrical billet between two flat dies so it becomes shorter and wider.
Forming Limit Diagram (FLD) & Strain Path Visualization Tool
Casting & Forming
Interactive forming limit diagram (FLD) using the Keeler-Goodwin FLC approximation. Visualize strain paths, adjust material thickness and work hardening index, and check…
Freeze Drying Process Calculator — Sublimation Rate & Drying Time
Calculate freeze drying times, sublimation rates, and energy use with this interactive tool. Input product type, temperature, and pressure.
Grinding Specific Energy Simulator
Compute the specific energy of grinding — the energy required to remove a unit volume of material — directly from the process parameters.
High Pressure Processing (HPP) Food Safety Simulator
Design a non-thermal pasteurization line that uses 400-800 MPa isostatic pressure to inactivate pathogens. Adjust pressure, holding time, target organism and product cat…
Injection Molding Cycle Time Optimization Simulator
Casting & Forming
Predict the per-shot cycle time of an injection-molded plastic part by splitting it into filling, cooling, plasticizing and ejection segments, with cooling computed from…
Injection Molding Fill Pressure & Cooling Time Calculator
Casting & Forming
Calculate injection molding fill pressure, cooling time, and cycle time instantly. Enter runner geometry, melt viscosity, and part thickness for fast results.
Cement Rotary Kiln Energy Balance Simulator
Change clinker output, kiln type (NSP/SP/wet) and fuel and immediately see specific heat consumption, daily heat duty, fuel mass, fuel-derived CO2, process (calcination)…
Laser Cutting Speed Estimator
Answer the everyday sheet-metal question — "at this laser power, on this plate thickness, how many metres per minute can I cut?" — with the standard energy-balance equat…
Machine Tool Spindle Thermal Growth & Precision Error Simulator
CNC spindles in machining centres, lathes and grinders grow by tens of micrometres while running, and quietly throw precision parts out of tolerance.
Turning Machining Power Simulator
Estimate how much power a turning operation on a lathe really takes.
Merchant Cutting Simulator — Orthogonal Cutting Force Analysis
Solve Merchant's equation φ = 45° + α/2 − β/2 for 2D orthogonal cutting. Vary tool rake angle α and tool-chip friction coefficient μ and watch the shear angle, friction …
Metal Cutting Simulator — Merchant Circle & Cutting Force
Calculate cutting forces with Merchant's theory. Visualize the Merchant circle and plot Taylor tool life in real time with this metal cutting simulator.
Milk Pasteurization HTST D-Z Value Simulator
Evaluate HTST (High Temperature Short Time), UHT and LTLT milk pasteurization from the D- and Z-values of pathogens. Change temperature, holding time, flow rate or targe…
Milling Chatter Stability Lobe Diagram Simulator
Predict the chatter vibration of milling with the Altintas-Budak Stability Lobe Diagram theory.
Plasma Etch Selectivity & Anisotropy Simulator
An interactive tool for SiO₂, Si, poly-Si and Al thin-film patterning by reactive ion etching (RIE).
Polymer Viscosity & Flow Analysis — Carreau-Yasuda, Power Law, Gate Pressure Drop
Casting & Forming
Compute polymer viscosity curves using Carreau-Yasuda & power-law models. Calculate gate pressure drop and cooling time for injection molding process analysis.
Punching & Blanking Press Force Simulator
Casting & Forming
Size the press force needed to punch a circular hole through sheet metal. Adjust punch diameter, sheet thickness and material shear stress to see the peak punch force, t…
Rolling Mill Force Simulator
Casting & Forming
Estimate flat rolling — squeezing a metal strip thinner between two rotating rolls.
Rosenthal Solution Simulator — Quasi-Stationary Welding Heat Transfer
Welding
Rosenthal solution simulator for welding heat transfer. Compute heat input Q, line energy q, cooling time t8/5 and HAZ width from voltage, current, speed, arc efficiency.
Semiconductor Yield & Defect Density Simulator
Compute wafer yield with four classic models — Poisson, Murphy, Seeds (Negative Binomial) and Bose-Einstein. Adjust die size, defect density D0, critical layer count and…
Sheet Metal Bending Calculator — Bend Allowance & Springback
Casting & Forming
Calculate bend allowance, flat length, and springback instantly. Input material, thickness, radius, and angle for accurate sheet metal bending results.
Spring-Back Simulator — Elastic Recovery in Sheet Metal Bending
Casting & Forming
Spring-back ratio K = 4X^3 - 3X + 1 with elastic parameter X = sigma_y R_i / (E t), unloaded inside radius R_f = R_i / K and 90 deg return angle delta_theta = 90 (1 - K)…
Turning Theoretical Surface Roughness Ra Simulator
Compute the theoretical surface roughness Ra and Rz of a turned surface in real time from the feed f, tool nose radius r_ε, cutting speed, lead angle and workpiece diame…
Surface Roughness Converter · Ra/Rz/Rq & Process Selection
Convert Ra, Rz, Rq & Rmax. Compare roughness by manufacturing process. ISO & ANSI reference guide for surface finish symbols and grades.
Taylor Tool Life Simulator
Explore the most famous empirical law in machining — Taylor's tool life equation V·Tⁿ=C. Adjust the cutting speed, Taylor exponent n and constant C to see tool life, par…
Weld HAZ Cooling Rate Simulator
Welding
Compute the cooling rate through the heat-affected zone (HAZ) of an arc weld using the Rosenthal-Adams analytical solution.
Welding Heat Input & Cooling Rate Calculator (Rosenthal Solution)
Welding
Calculate welding heat input and cooling rates with the free Rosenthal solution calculator from . Optimize your welding parameters for better results.
Welded Joint Strength Calculator (AWS D1.1)
Welding
Calculate welded joint strength per AWS D1.1. Instantly find allowable load, safety factor, and eccentric effects for fillet and PJP welds.
Welding Residual Stress Simulator — Heat Input, Distortion & Shrinkage
Welding
Simulate welding residual stress, distortion, and shrinkage. Adjust heat input, material, joint type, and restraint for instant engineering calculations.
Semiconductor Wire Bonding Pull Test Strength Simulator
Estimate the pull-test strength of Au / Al / Cu / Pd-Cu bond wires that connect an IC die to a lead frame or PCB.
How to Use
- Select your manufacturing process from the dropdown: machining, casting, welding, forming, or additive manufacturing
- Input material properties (aluminum 6061-T6: E=69 GPa, yield=276 MPa; steel 1045: E=205 GPa, yield=310 MPa)
- Define process parameters: spindle speed (RPM), feed rate (mm/min), tool geometry, or layer thickness for AM
- Run simulation to generate tool stress maps, temperature fields, residual stress distributions, and cycle time predictions
- Export results as CSV or visualize deformation contours and heat flux
Worked Example
CNC turning operation on aluminum 6061-T6 bar (diameter 40mm, length 150mm): spindle speed 1200 RPM, feed rate 0.15 mm/rev, cutting depth 2mm. Simulator calculates tool stress (245 MPa at insert nose), chip temperature (680°C), cutting force (420 N), and tool life (285 minutes before wear criterion reached). FEA mesh refines near tool-chip interface with 0.1mm elements. Residual stress profile shows maximum compression 120 MPa at 0.3mm subsurface depth.
Practical Notes
- For investment casting of ductile iron (3.5% carbon): simulate mold fill time, solidification fronts, and shrinkage porosity risk zones; refine mesh near gates to 2mm resolution
- Welding simulations require heat source definition (GMAW 180A, travel speed 350 mm/min); track HAZ softening in 6061-T6 aluminum where strength drops 15-20%
- Additive manufacturing (DMLS titanium): layer thickness 40 microns, laser power 200W, scan speed 800 mm/s; monitor thermal stress between 0.2-0.5mm depth for cracking risk
- Sheet metal forming: use anisotropic plasticity for rolled aluminum; friction coefficient 0.12 with tool; predict springback angles within 0.5 degrees