Machining with Planer Simulation

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. Case one will be with a cutting velocity of 20000mm/s and case two will be with a cutting velocity of 15000mm/s.

SOLUTION:

Step 1: Part model and material

The model was used as given and the material for the workpiece was taken as steel 1006. Since the focus of the analysis is only on the workpiece, the cutting tool was defined as rigid.

Step 2: Meshing

The part was meshed using ANSYS Mesher. The cutting tool was meshed with tetrahedron elements using patch conforming method and the workpiece was meshed such that each of the smaller edges has 10 divisions.

Step 3: Analysis settings

The analysis is carried out in a single step, with the end time step = 7.5e-4. The bottom face of the workpiece was given fixed condition and the tool was given a velocity of 20000mm/s and 15000mm/s in the X direction.

Step 4: Results

Case 1: Velocity = 20000mm/s

Case 2: Velocity = 15000mm/s

Case	Maximum equivalent stress (MPa)	Maximum total Deformation (mm)	Max temperature developed (oC)
Vel = 20000mm/s	492.44	29.259	376.95
Vel = 15000mm/s	634.34	23.176	363.51

The maximum value for the deformation and temperature developed is in case 1, while the maximum stress is developed in case 2. The relation between cutting force and cutting velocity is such that, it decreases with increasing velocity. Due to the lower force, the stress developed is also lower in case 1. The total deformation is larger in case 1 because the velocity is higher in this case, hence the tool travels a longer distance in the same given time. Due to this longer travel, the machined surface is also large. This results in a higher temperature being developed in case 1.