Week 9 Machining with Planer Challenge

OBJECTIVE 

To perform an explicit dynamics of machining operation with a planer cutting tool.

Case 1 Cutting Velocity of 20000 mm/s

Case 2  Cutting Velocity of 15000 mm/s

Find out the equivalent stress , Total Deformation and temperature of the body.

PRODECURE

Case 1 Cutting velocity of 20000mm/s

Create Explicit dynamics in Ansys workbench and in engineering data select the material steel 1006 from explicit material and strutural steel

Steel 1006

Import the geometry and check in Spaceclaim for any irregularties

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 Interaction    No interactions are defined .Instead of a body Interaction is introduced the parameters of which are set as shown below

  

Mesh    The cutting tool is measured by patch conforming method using tetrahedron elements

 

                                                  

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

                                                  

Mesh 

                                             

Analysis Setting   Set end time as 7.5e-4 with maximum number of  cycle 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 - 29.259mm

                                               

                                              

Equivalent Stress Max - 492.21 Mpa

                                                    

                                                   

Temperature  Max - 376.95 degree Celsius 

                                                  

                                                  

Cutting Tool Displacement - 15mm

                                                       

Energy Conversion Plot

                                               

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 cycle 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 - 23.175mm

                                               

                                               

Equivalent Stress Max - 634.3Mpa

                                              

                                              

Temperature Max - 363.51 Degree Celsius 

                                                 

                                                  

Cutting Tool Displacement - 11.25mm

                                             

Energy Conservation plot

                                           

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 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 the case 2
• Both the simulation run successfully with the maximum energy errors of 0.1 and 0.14 for case 1 and case 2 respectively.