Machining with Planer Challenge

OBJECTIVE - To perform an explicit dynamics simulation to find out the Equivalent Stress, Total Deformation and also insert a User defined result to calculate the temperature of the body. You need to perform this for 2 cases. One will be with a cutting velocity of 20000mm/s and the other will be with a cutting velocity of 15000mm/s.

GEOMETRY-

MATERIALS -

Structural Steel - The Planar is assigned Structural Steel

Steel 1006 - The workpiece is assigned Steel 1006 . The material has explicit behaviour defined by Johnson Cook Strength.

MESHING - The planaer is meshed with Tetrahedons and the Workpiece is meshed with hexagons using 10 elements through thickness.

ANALYSIS SETTINGS -

THe simulation is run for 7.5 E-4 s and the maximum no of cycles is 1e+7. Also energy error is kept to 0.1.

FIXED SUPPORT

VELOCITY - In CASE 1 the velocity is 20000mm/s and 15000mm/s in CASE 2.

RESULTS-

CASE 1 - velocity 20000mm/s

EQUIVALENT STRESS - 439 MPa

TOTAL DEFORMATION - 13.64 mm

MAXIMUM TEMPERATURE- 367.77 Deg

PLANAR TRAVEL - 15mm

CASE 2 - velocity 15000mm/s

EQUIVALENT STRESS - 634.2 MPa

TOTAL DEFORMATION - 13.67 mm

MAXIMUM TEMPERATURE- 298.44 Deg

PLANAR TRAVEL - 11.25 mm

Conclusion -

1. The equivalent stress in Case 1 with higher velocity is lower because the Workpeice in case 2 offers higher resistance to tool as it moves with lower velocity of 15000mm/s and unable to cut the whole workpiece.

2. THe case 1 has higher temperature as compared to Case 2 as it has higher Material removal and higher strain as compared to Case 2.