Week 9 Machining with Planer Challenge
Ansys Week 9: Machining with Planar Challenge
AIM
To perform the explicit dynamics simulation on the cutting tool using workpiece as the steel 1006 material.
OBJECTIVE
The objective of this challenge is to perform the explicit dynamic analysis to find equivalent stress, total deformation, and temperature of the body using user-defined results for two cases.
Case 1: Cutting Velocity of 20,000m/s and
Case 2: 15,000m/s.
MATERIAL PROPERTIES
Steel 1006
Fig 1: Steel 1006 Properties
PROCEDURE
Setup
Import the geometry in the space claim to check the geometry and the surface if any of them is damaged to ensure the geometry perfection.
Fig 2: Geometry
After checking the geometry open the file in the mechanical module and rename the part as a workpiece and cutting tool.
The auto contacts are given and detected by the Ansys workbench but this not required for the evaluation of the machining with the planar, so it is deleted for this analysis.
Mesh
For the cutting tool, tetra mesh is deployed by selecting the batch conforming method and selecting the method as tetrahedrons.
Fig 3: Patch conforming method
For the workpiece to deploy the mesh properly a new concept is done with selecting the edges as an edge sizing and types as the number of the division with the division of 10.
Fig 4: Edge sizing
Analysis settings
For analysis settings, the end time is given as 0.00075 with the initial, maximum, and minimum time to be as program-controlled.
Fig 5: Analysis Settings
For Case 1 for the x component the 20000 mm/s and the y and z as a constant.
For case 2 for the x component the 15000 mm/s and the y and z, a constant but while simulation it gave the error of energy is too large so the maximum energy error is 0.15.
Fig 6: Velocity Case 1
Fig 7: Velocity Case 2
And the fixed support is given to the work[eice so while simulating it should not move.
Fig 8: Fixed support
RESULTS
Case 1: Velocity 20000 mm/s
Total deformation
Fig 9: Total deformation v20000
Equivalent von mises stress
Fig 10: Equivalent stress v20000
User-defined result temperature
Fig 11: Temperature v20000
Case 2: Velocity 15000 mm/s
Total deformation
Fig 12: Total deformation v15000
Equivalent von mises stress
Fig 13: Equivalent stress v15000
User-defined result temperature
Fig 14: Temperature v15000
CONCLUSION
The simulation runs successfully as the observation for both the cases while evaluating the results, the materials fly off as elements are cut off while cutting the planar.
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File link: https://drive.google.com/drive/folders/1UZ9UIHWB1i4b9XI6xhZF4qkrN2fUHCGg?usp=sharing