Week 9 Machining with Planer Challenge
Objective:
To perform explicit dynamics simulation to find out Equivalent Stress, Total Deformation and to insert a user defined result to calculate the temperature of the body. There are two cases one with cutting velocity of 20000 mm/s and other with 15000 mm/s.
Setup:
We need to add the material Steel 1006 from explicit materials in engineering sources. Once the material is added we import the material into the geometry and open in spaceclaim to check for a y abnormalaties. Once it is checked we go ahead and load the model in the mechanical module. After opening in mechanical module rename the parts as cutting tool and workpiece, while giving the cutting tool a rigid behaviour and giving the material steel 1006 to the workpiece. After that is done the default contact created is deleted and body interaction is made to frictionless. Moving onto mesh we give a method sizing to the cutting tool and a sizing by selecting the edges of the workpiece. After that we give number of division as 10. Once the mesh is generated we go onto analysis settings where we give end time as 7.5e-4 s and leave everything as default but in the case where the velocity is 15000mm/s we give the maximum energy error as 1.2. After that a fixed support is given to the workpiece by selecting the bottom of the workpiece as the geometry and then a velocity is given in the global x coordinate according to the case. Both y and z are given value 0 to keep it from moving in any other direction. In solution add total deformation, Equivalent Stress and Equivalent strain. Once solved, from the worksheet select the temperature and create a user defined result and evaluate to find it out.
Case 1 (20,000mm/s):
Total Deformation:
The maximum amount of deformation caused by the small particles in projectile is 86.202mm.
Equivalent Strain:
The maximum amount of strain produced by the seperated particles are 0.0031925mm/mm
Equivalent Stress:
The maximum amount of stress produced was 671.14 MPa.
Temperature:
The maximum amount of temperature produced was 367.35 degree celsius.
Case 2 (15,000 mm/s):
Total Deformation:
Thre total deformation that was caused was 11.65 mm
Equivalent Strain:
The maximum amount of equivalent strain is 0.0034022 mm/mm.
Equivalent Stress:
The maximum amount of stress produced was 693.12 MPa.
Temperature:
The maximum amount of temperature caused is 309.77 degree celsius.
Conclusion:
| Velocity | 20,000 mm/s | 15,000 mm/s |
| Total Deformation (mm) | 86.202 | 11.65 |
| Equivalent Stress (MPa) | 671.14 | 693.12 |
| Equivalent Strain (mm/mm) | 0.0031925 | 0.0034022 |
| Temperature | 367.35 | 309.77 |
The case with 22,000 mm/s produced higher total deformation and temperature but less Stress and Strain. For the model with 22,000 mm/s the cutting tool went through the entire piece while for the other model with 15,000 mm/s only went through half of the workpiece. The higher stress and strain in the slower case maybe due to stoppage of the cutting model halfway through, also the higher temperature and higher deformation can be down to the fact that the cutting tool cuts through the whole workpiece. The temperature is also higher at the surface of the workpiece where the cutting occurs