Week 9 Machining with Planer Challenge

A) TITLE:- Machining with shaper simulation using ansys workbench 2019 V3.

B) OBJECTIVE :- To simulate the workpiece machining with shaper operation to study different parameters like equivalnet stress , total deformation , temeperature generated etc.

C) MODELING :- The model consisiting of a rectangular workpiece and a tool is imported into the dynamic explicit analysis module. 

D) ANALYSIS :-

When the workpiece is stationary and the tool moves against it then it is called as shaping operation while when the tool is stationary and workpiece is moving against it then it is called as planning operation. in this simulation , workpiece will be stationary hence it is a shaping operation.

1) The workpiece is assigned with explicit material steel 1006 while the tool is assigned with structural steel. 

2) No conatcts and joints are required to be generated in this model.                                                    

3) The workpiece and tool bot are meshed with 0.3 mm mesh size.

4)The analysis is carried out for a very short span of time with end time as 7.5e-4 sec. as this is a very short period phenomenon with large deformation , hence a dynamic explict module has to be used for the analysis.

5)The workpiece is made fixed while the cutting tool is assigned with linear velocity of 20,000 mm/sec and 15000 mm/sec in two different cases.

6) the simulation is then carried out and the results obtained are summarized below:-

E) RESULTS :-

I) CASE 1 :- VELOCITY OF CUTTING TOOL=20000 MM/SEC

             

             

                     

II) CASE 2 :- VELOCITY OF CUTTING TOOL=15000 MM/SEC

                          

                         

                        

all results are tabulated below :-

               

F) DISCUSSIONS :-

The graph of different properties vs the cutting speed for shaper is given below:-

I) The maximum total deformation ( 35.27 mm) is found to be in case -1 with V=20000 mm/sec. as the speed of the tool is higher than case-1 it will travel more distance in the specified time. from the result images also it can be observed that the tool has reached almost at the end of the workpiece in case-1. aslo from graph it can be seen that with incarease in cutting speed the MRR incareases. the same can be observed with the simulation.

II) The maximum stress (688 MPa) is found to be in case-1 with V=20000 mm/sec.

III) The temperature of workpiece is maximum (369.35 C) for case -2 with V=15000 mm/sec. also it can be observed that with increase in speed the maximum temperature rise in workpiece has reduced. the graph also indicates the same. with reduction in cutting speed the chip formed remains in conatct with workpiece for longer time and thus heat gets transferred to workpiece. thus the temperature increases.

note :- the simulation result video files are attached herewith.