Week 9 Machining with Planer Challenge
Title: Machining with shaper using Ansys Workbench.
Objective:
We have to perform an explicit dynamics simulation to find out the Equivalent Stress, Total Deformation and also insert a User defined result to calculate the temperature of the body. You need to perform this for 2 cases. One will be with a cutting velocity of 20000mm/s and the other will be with a cutting velocity of 15000mm/s.
Analysis:
When the workpiece is stationary and tool goes against it that is called shaping operation and if tool is stationary and workpiece is moving against it that is called planar operation.In this simulation we are doing shaping operation.
1. The workpiece is assigned with Explicit material Steel 1006 and the tool is assigned with Structural steel
2. No contacts and joints are required for this model.
3.Meshing for tool is done with tetrahyderan elements so as to capture complex geometry with default mesh size and workpiece sides are divided into 8 divisions and meshed.
4.The analysis is carried out for a very short span of time with end time of 7.5e-4 sec. As this is short period phenomenon with large deformation, hence Dynamic explicit model is used for analysis.
5.Fixed support is given to workpiece and velocity of 20000m/s and 15000m/s is assigned to tool against workpiece in tow different cases.
6. Simulation is carried out and results are summerised below:
Results
Case 1: Velocity of tool = 20000mm/s
Case 2: Velocity of tool = 15000mm/s
Tabulate the results below as per simulation:
| Case | Cutting Velocity(mm/s) | Max. Equivalent Stress | Max Total Deformation | Max. Temperature |
| 1 | 20000 | 653.32 | 26.703 | 362.07 |
| 2 | 15000 | 667.38 | 22.642 | 360 |
Conclusions:
1.Max equivalent stress is greater in case 2(667.38) than in case 1(653.32).
2.Max total deformation in case 1 is 26.703 and in case 2 is 22.642. Material removal rate decreases when speed of cutting tool is decreased.
3. Max.Temperture is less for case 2(360 c) compared to case 1(362.07 c)