Planing Operation Analysis on a Carbon steel 1006 workpiece

Planing Operation Analysis on a Carbon steel (1006) workpiece

Linear planning is associated with shearing off a top layer of a workpiece/uneven surface to plane or flatten the top. In this simulation, the effect of two different velocities is examined on a workpiece to study its after-effects.

Geometry

Tool (dark grey) against the workpiece

For analysis purposes, the workpiece is assigned an explicit material of Steel 1006 (flexible material behavior) and the cutting tool is assigned structural steel with rigid behavior to facilitate rigid body motion with no deformation.

Meshing/Pre-processing

Meshed model

The mesh is generated as follows:

1. A tetrahedral patch conforming method is assigned to the cutting tool.
2. The 4 short (vertical) edges of the workpiece are assigned edge sizing of 10 divisions to obtain the mesh as shown above

Any pre-existing contacts are removed in order to facilitate tool movement. The cutting tool is assigned a value of velocity in the X-direction and the y and z components are assigned a zero value to restrict any motion in those directions. The bottom face of the workpiece is assigned a fixed support to simulate fixture.

Under the analysis settings, the end time is assigned to be 0.00075 seconds to simulate a high energy short duration dynamic event where the maximum number of cycles are assigned to be of the order of 10⁷.

For the analysis with v = 15k mm/s, the number of reference energy cycles is equated to the maximum number of cycles (i.e.10⁷) to avoid any iteration(s) facing energy errors interfering with the solver over the period of the solution.

Post-processing

The model is solved for computing directional deformation, equivalent stress, plastic deformation and body temperatures.

@ velocity = 15000 mm/s

Max eq stress Directional deformation

@ velocity = 20000 mm/s

Max eq stress Directional deformation

Parameters (all max over time)	@ 20k mm/s	@ 15k mm/s
Total Deformation	25.70 mm	20.30 mm
Equivalent stress	676.44 MPa	675.1 MPa
Equivalent strain	149.79%	149.84%
Temperature	376.950C	363.510C

Conclusion

It is observed that the tool travels the complete length of the workpiece while traveling at 20k mm/s and the maximum values of stress and plastic strain over time for the planning operations at both the speeds remain the same (however, the final stress of the operation for v=20k mm/s is significantly lower due to minimal accumulation of residual stress and results in a smoother finish – no significant chip fracture observed). A higher directional deformation is observed in the case with higher speed due as the material is sheared off with a higher force (keeping momentum conservation in mind). It is evident that the chipped off material for planing at higher speeds will have higher temperature as per energy conservation principles.