Machining With Planer

The challenge for the machining with the planer was carried out by using Explicit Dynamics from the Ansys Workbench.

For this project, the material was first specified using Engineering Data from the engineering data sources. It was kept at Structural Steel. The details of this material are mentioned below.

The geometry was imported into the mechanical DUI and opened in SpaceClaim for editing purposes. The parts were renamed as Workpiece and Cutting Tool The details of this geometry are given below.

Work Piece

Cutting Tool

For the connections, the default connections were deleted as they were bonded in nature. The default body interactions kept were used, being frictionless in nature. The details of this connection are shown below.

The mesh was kept at default. A patch conforming method of sizing was used for the cutting tool. It specified the method of mesh to be tetrahedral. An edge sizing was used for the small corners of the workpiece. The details of this mesh are mentioned below.

Mesh

Patch Conforming Method

Edge Sizing

The analysis settings were slightly modified keeping the time step to be one. The details are as follows.

The velocity was specified for the cutting tool in the x-axis direction. The details –

A fixed support was inserted for the work piece to prevent it from moving during the machining process. The details are mentioned below.

For the solution, the conditions mentioned were, directional deformation, equivalent stress, equivalent plastic strain. The minimum and maximum values for these conditions are given below along with the details.

Condition	Minimum Value	Maximum Value
Directional Deformation	-19.692mm	28.715mm
Equivalent Stress	1.0429MPa	649.56MPa
Equivalent Plastic Strain	1.4447e-7mm/mm	1.6413mm/mm

Directional Deformation

Equivalent Stress

Equivalent Plastic Strain

Case 2

The velocity specified earlier for the cutting tool, was changed from 20000m/s to 15000m/s. The details of these changes are shown below.

After making this change, the simulation was carried out.

For the solution, the conditions mentioned were, directional deformation, equivalent stress, equivalent plastic strain. The minimum and maximum values for these conditions are given below along with the details.

Condition	Minimum Value	Maximum Value
Directional Deformation	-15.666mm	17.249mm
Equivalent Stress	2.5531MPa	668.52MPa
Equivalent Plastic Strain	0	1.5617mm/mm

Directional Deformation

Equivalent Stress

Equivalent Plastic Strain

COMPARISON
The directional deformation is maximum when the velocity of the cutting tool is 20000m/s with the value of 28.715mm. When the equivalent stress is considered, it is more when the velocity is 15000m/s, the value being 668.52MPa. In case of the equivalent plastic strain, the maximum value is in the first case where the velocity is 20000m/s, with the value of 1.6mm/mm.