Machining with Planer using Ansys

Objective - To perform an explicit dynamics analysis of Machining operation with a Planer cutting tool.

Case 1 - Cutting velocity of 20000mm/s.

Case 2 - Cutting velocity of 15000mm/s.

Find out the Equivalent Stress, Total Deformation and temperature of the body.

Procedure -

Case 1 - Cutting velocity of 20000mm/s.

Create Explicit Dynamics in Ansys workbench and in engineering data select the material Steel 1006 from explicit materials and Structural Steel.

Structural Steel.

Steel 1006.

Import the geometry and check in SpaceClaim for any irregularities.

Then open Ansys mechanical and rename the component as Workpiece and Cutting Tool then assign the Steel 1006 material to the Workpiece and Structural Steel material to the Cutting Tool and change the stiffness behaviour of the cutting tool to Rigid.

Body Interactions - No contacts are defined. Instead a Body Interaction is introduced, the parameters of which are set as shown below.

Mesh - The Cutting Tool is meshed by Patch Conforming Method using Tetrahedron elements.

Edge Sizing - The workpiece is meshed by defining 10 elements along its edges.

Mesh

Analysis Settings - Set end time as 7.5e-4, with maximum number of cycles as 1e+7, Maximum error set to 0.1.

Fixed Support - Workpiece is fixed.

Velocity - Cutting Tool provides the velocity of 20000mm/s.

Run the simulation and results obtained.

Result - The analysis runs successfully and results obtained.

Total Deformation Max - 29.259 mm

Equivalent Stress Max - 492.21 Mpa

Temperature Max - 376.95 Degree Celsius

Cutting Tool Displacement - 15 mm

Energy Conservation Plot

Animation - Equivalent Stress

Case 2 - Cutting velocity of 15000mm/s.

Velocity - Cutting Tool provides the velocity of 15000mm/s.

In Analysis setting - Set end time as 7.5e-4, with maximum number of cycles as 1e+7, Maximum error set to 0.14.

Other setup Same as Case 1

Run the simulation and results obtained.

Result - The analysis runs successfully and results obtained.

Total Deformation Max - 23.175 mm

Equivalent Stress Max - 634.3 Mpa

Temperature Max - 363.51 Degree Celsius

Cutting Tool Displacement - 11.25 mm

Energy Conservation Plot

Animation - Equivalent Stress

Conclusion -

• Equivalent Stress is lower in Case 1 as the cutting tool has already removed the intended amount of material from the specimen due to high velocity.
• The Case 1 has higher temperature as compared to Case 2 as it removes more material as compared to Case 2.
• Run time is constant in both Cases, a reduction in the feed velocity reduces the amount of material removed from the workpiece. This is evident from the Total displacement of the cutting tool, which displaces 15mm in Case 1 and 11.25mm in Case 2.
• Both the simulations run successfully with the maximum energy errors of 0.1 and 0.14 for Case 1 and Case 2 respectively.

Google drive link - https://drive.google.com/file/d/1-fahiGByy1ruubg1Kv-vwKKuR_4WTZCy/view?usp=sharing