Week 9 Machining with Planer Challenge

Objective:

To perform an explicit dynamics simulation to find out the Equivalent Stress, Total Deformation and temperature of the body for following cases;

Case 1: cutting velocity at 20000mm/s

Case 2: cutting velocity at 15000mm/s.

aim is to simulate the machining with planer process in Ansys Workbench and find results for Equivalent Stress, Total Deformation and temperature

Geometry:

Material:

for work piece;

Mesh:

Meshing method for cutting tool is kept as tetrahedrons since the tool geometry is complex geometry,

the workpiece mesh is meshed with respect to division of 10 on small edgs.

no of nodes: 7704

no of elements: 8293

Boundary Conditions:

• Velocity of 20000mm/s and 15000mm/s is applied to the cutting tool in positive x direction for case 1 and 2 respectively.

• Fixed support is added to the base of the workpiece so that there is no movement of the workpiece while machining.

Analysis Settings:

• Following analysis settings have been used for the simulation with an end time of 0.00075 seconds.

Results:

Case 1: cutting velocity at 20000mm/s ;

Equivalent Stress:

Total Deformation:

Temperature:

Case 2: cutting velocity at 15000mm/s.

Equivalent Stress:

Total Deformation:

Temperature:

CONCLUSION:

Analysis	Case 1	Case 2
Max Equivalent Stress	656.99 MPa	661.73 MPa
Max Total Deformation	32.53 mm	28.857 mm
Temperature	374.76 degree C	399.29 degree C

From the above results,

As the velocity of the tool increases while machining, the max stress induced on the workpiece increases and the directional deformation also increases. The max equivalent plastic strain is almost the same in both the cases. The temperature also increases with increase in cutting tool velocity.