Week 9 Machining with Planer Challenge

Aim: To conduct an explicit dynamics simulation of machining of a planar surface. This will be done for two cutting velocities 20000 mm/s and 15000 mm/s.

Procedure:

Materials: Go to engineering data and import Steel 1006 from explicit materials.

Geometry: Drag and drop the geometry in space claim to upload it.

Setup:

Components: Name the bodies as workpiece and cutting tool. Assign steel 1006 to the workpiece and structural steel to the cutting tool. Set the cutting tool as a rigid body.

Mesh:

• Assign edge sizing on the workpiece. The number of divisions is 10.
• Add a tetrahedron mesh method on the cutting tool.

Analysis Settings: The number of time steps is 1 and the end time is 7.5e-04s.

Load Settings:

• Assign a constant velocity load of 20000 mm/s or 15000 mm/s on the cutting tool depending on the case.
• Then set a fixed load condition to the bottom face of the workpiece.

Solution: Equivalent stress and total deformation of the workpiece must be obtained for both cases. Along with that, the temperature is obtained by the user-defined function TEMPERTUREALL.

Results & Discussion:

Case 1: 20000 mm/s

The maximum stress experienced at the end of the time step is 492.21 MPa.

The total maximum deformation is 29.259 mm. This increases linearly in time.

The maximum temperature is 376.95 C.

Case 2: 15000 mm/s

The maximum stress experienced at the end of the time step is 634.5 MPa. Here as the cutting tool does not reach the end of the workpiece we do not observe a sudden drop in the stress as seen in the previous case.

The maximum total deformation is 28.206mm.

Here as the speed is less there is a reduced temperature in the interface ad the maximum temperature is 338.88 C.

Conclusion: Machining of a planar workpiece was performed for two different speeds and it is observed that slower machining leads to more stress and lower temperatures.