Machining with Planer Challenge
Aim:
To perform explicit dynamics simulation of a cutting tool on a workpiece.
Objective:
We will 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.
Procedure:
At first we will be importing the geometry model into the ANSYS-WORKBENCH and check for any geometrical errors.
And now we will be providing patch confirming method for meshing and face sizing on the edges of the workpiece since it is rectangular and so we will get a refined and proper mesh for better and accurate results. The areas to be selected are as shown in the image below.
The final meshed model is as shown in the two images below.
After meshing we will be setting the boundary conditions for the case setup model. The first one will be velocity for the cutting tool at 20000 mm/s as shown in the image below.
The next one will be to provide fixed support for the workpiece and the face to be selected is as shown in the image below.
Similarly, we will be running the simulation for another case with a velocity of 15000 mm/s.
Simulation:
Case 1:
Total Deformation:
|
Time [s] |
Minimum [mm] |
Maximum [mm] |
Average [mm] |
|
|
1 |
1.18E-38 |
0 |
0 |
0 |
|
2 |
3.75E-05 |
0 |
0.79467 |
2.53E-02 |
|
3 |
7.50E-05 |
0 |
1.7516 |
6.68E-02 |
|
4 |
1.13E-04 |
0 |
2.9441 |
0.11954 |
|
5 |
1.50E-04 |
0 |
4.2506 |
0.18808 |
|
6 |
1.88E-04 |
0 |
5.6467 |
0.28285 |
|
7 |
2.25E-04 |
0 |
7.0432 |
0.399 |
|
8 |
2.63E-04 |
0 |
8.4401 |
0.54174 |
|
9 |
3.00E-04 |
0 |
9.9252 |
0.70447 |
|
10 |
3.38E-04 |
0 |
11.522 |
0.88623 |
|
11 |
3.75E-04 |
0 |
13.124 |
1.085 |
|
12 |
4.13E-04 |
0 |
14.731 |
1.3023 |
|
13 |
4.50E-04 |
0 |
16.34 |
1.5351 |
|
14 |
4.88E-04 |
0 |
17.951 |
1.7742 |
|
15 |
5.25E-04 |
0 |
19.564 |
2.0176 |
|
16 |
5.63E-04 |
0 |
21.178 |
2.282 |
|
17 |
6.00E-04 |
0 |
22.793 |
2.5668 |
|
18 |
6.38E-04 |
0 |
24.409 |
2.8663 |
|
19 |
6.75E-04 |
0 |
26.025 |
3.2 |
|
20 |
7.13E-04 |
0 |
27.642 |
3.6019 |
|
21 |
7.50E-04 |
0 |
29.259 |
4.0059 |
Simulation Video - https://drive.google.com/file/d/1cFqzls3vOW2Nym2VcKe2DwkbMaR6Z72S/view?usp=sharing
Equivalent Stress:
|
Time [s] |
Minimum [MPa] |
Maximum [MPa] |
Average [MPa] |
|
|
1 |
1.18E-38 |
0 |
0 |
0 |
|
2 |
3.75E-05 |
1.4466 |
674.06 |
141.29 |
|
3 |
7.50E-05 |
1.5056 |
676.75 |
136.83 |
|
4 |
1.13E-04 |
1.4057 |
650.1 |
142.29 |
|
5 |
1.50E-04 |
2.7674 |
663.84 |
140.27 |
|
6 |
1.88E-04 |
1.8502 |
637.16 |
132.38 |
|
7 |
2.25E-04 |
1.4918 |
644.02 |
140.97 |
|
8 |
2.63E-04 |
1.1994 |
638.71 |
143.81 |
|
9 |
3.00E-04 |
1.9255 |
673.79 |
160.71 |
|
10 |
3.38E-04 |
1.1256 |
639.48 |
151.63 |
|
11 |
3.75E-04 |
0.66068 |
658.5 |
157.83 |
|
12 |
4.13E-04 |
2.7309 |
636.93 |
167.7 |
|
13 |
4.50E-04 |
0.83417 |
652.89 |
142.93 |
|
14 |
4.88E-04 |
4.016 |
649.89 |
182.98 |
|
15 |
5.25E-04 |
0.82874 |
640.39 |
178.73 |
|
16 |
5.63E-04 |
2.1104 |
636.53 |
191.63 |
|
17 |
6.00E-04 |
0.95489 |
640.13 |
198.4 |
|
18 |
6.38E-04 |
4.3439 |
658.07 |
201.2 |
|
19 |
6.75E-04 |
1.6731 |
618.86 |
182.28 |
|
20 |
7.13E-04 |
2.7207 |
656.69 |
185.06 |
|
21 |
7.50E-04 |
1.2632 |
492.41 |
113.95 |
Simulation Video - https://drive.google.com/file/d/1iFIMntmk56PVyKJvZ1ZjFY_KZ2U8OOzj/view?usp=sharing
Temperature:
|
Time [s] |
Minimum [°C] |
Maximum [°C] |
Average [°C] |
|
|
1 |
1.18E-38 |
19.85 |
22 |
21.473 |
|
2 |
3.75E-05 |
19.85 |
274.16 |
26.176 |
|
3 |
7.50E-05 |
19.85 |
322.16 |
31.198 |
|
4 |
1.13E-04 |
19.85 |
362.1 |
35.615 |
|
5 |
1.50E-04 |
19.85 |
369.32 |
39.512 |
|
6 |
1.88E-04 |
19.85 |
376.95 |
43.291 |
|
7 |
2.25E-04 |
19.85 |
376.95 |
46.922 |
|
8 |
2.63E-04 |
19.85 |
376.95 |
50.761 |
|
9 |
3.00E-04 |
19.85 |
376.95 |
54.383 |
|
10 |
3.38E-04 |
19.85 |
376.95 |
58.173 |
|
11 |
3.75E-04 |
19.85 |
376.95 |
62.032 |
|
12 |
4.13E-04 |
19.85 |
376.95 |
65.71 |
|
13 |
4.50E-04 |
19.85 |
376.95 |
69.415 |
|
14 |
4.88E-04 |
19.85 |
376.95 |
73.137 |
|
15 |
5.25E-04 |
19.85 |
376.95 |
77.134 |
|
16 |
5.63E-04 |
19.85 |
376.95 |
80.801 |
|
17 |
6.00E-04 |
19.85 |
376.95 |
84.667 |
|
18 |
6.38E-04 |
19.85 |
376.95 |
88.355 |
|
19 |
6.75E-04 |
19.85 |
376.95 |
92.01 |
|
20 |
7.13E-04 |
19.85 |
376.95 |
94.871 |
|
21 |
7.50E-04 |
19.85 |
376.95 |
95.497 |
Simulation Video - https://drive.google.com/file/d/1ortZDmY4Zflfzr9WfMtuxbSP5FLmAfWW/view?usp=sharing
Case 2:
Total Deformation:
|
Time [s] |
Minimum [mm] |
Maximum [mm] |
Average [mm] |
|
|
1 |
1.18E-38 |
0 |
0 |
0 |
|
2 |
3.75E-05 |
0 |
0.59555 |
1.69E-02 |
|
3 |
7.50E-05 |
0 |
1.3566 |
4.31E-02 |
|
4 |
1.13E-04 |
0 |
2.4148 |
7.82E-02 |
|
5 |
1.50E-04 |
0 |
3.4786 |
0.12108 |
|
6 |
1.88E-04 |
0 |
4.5438 |
0.1719 |
|
7 |
2.25E-04 |
0 |
5.6096 |
0.23644 |
|
8 |
2.63E-04 |
0 |
6.6761 |
0.31635 |
|
9 |
3.00E-04 |
0 |
7.7424 |
0.40886 |
|
10 |
3.38E-04 |
0 |
8.8092 |
0.51689 |
|
11 |
3.75E-04 |
0 |
9.8758 |
0.6346 |
|
12 |
4.13E-04 |
0 |
10.943 |
0.76508 |
|
13 |
4.50E-04 |
0 |
12.009 |
0.90619 |
|
14 |
4.88E-04 |
0 |
13.076 |
1.0571 |
|
15 |
5.25E-04 |
0 |
14.143 |
1.2168 |
|
16 |
5.63E-04 |
0 |
15.21 |
1.3835 |
|
17 |
6.00E-04 |
0 |
16.277 |
1.5581 |
|
18 |
6.38E-04 |
0 |
17.344 |
1.7327 |
|
19 |
6.75E-04 |
0 |
18.474 |
1.9142 |
|
20 |
7.13E-04 |
0 |
19.627 |
2.1035 |
|
21 |
7.50E-04 |
0 |
20.796 |
2.3063 |
Simulation Video - https://drive.google.com/file/d/11C9JzADjDafr6Y3tkX8UJSL3otG_XbDU/view?usp=sharing
Equivalent Stress:
|
Time [s] |
Minimum [MPa] |
Maximum [MPa] |
Average [MPa] |
|
|
1 |
1.18E-38 |
0 |
0 |
0 |
|
2 |
3.75E-05 |
1.2463 |
637.9 |
127.08 |
|
3 |
7.50E-05 |
0.83425 |
668.28 |
134.31 |
|
4 |
1.13E-04 |
1.4784 |
674.38 |
139.06 |
|
5 |
1.50E-04 |
1.6836 |
658.86 |
138.51 |
|
6 |
1.88E-04 |
0.84276 |
641.11 |
137.07 |
|
7 |
2.25E-04 |
0.61746 |
652.58 |
121.18 |
|
8 |
2.63E-04 |
3.59 |
674.22 |
146.05 |
|
9 |
3.00E-04 |
4.0871 |
660.25 |
137.52 |
|
10 |
3.38E-04 |
2.1674 |
632.27 |
150.65 |
|
11 |
3.75E-04 |
3.0135 |
643.16 |
143.75 |
|
12 |
4.13E-04 |
1.7536 |
633.56 |
152.5 |
|
13 |
4.50E-04 |
2.0432 |
639.54 |
144.79 |
|
14 |
4.88E-04 |
1.3386 |
628.78 |
156.33 |
|
15 |
5.25E-04 |
2.0391 |
623.96 |
165.54 |
|
16 |
5.63E-04 |
2.7913 |
633.89 |
155.69 |
|
17 |
6.00E-04 |
9.6012 |
649.88 |
153.23 |
|
18 |
6.38E-04 |
6.3324 |
648.3 |
140.02 |
|
19 |
6.75E-04 |
5.8573 |
672.45 |
188.62 |
|
20 |
7.13E-04 |
6.0594 |
655.8 |
180.87 |
|
21 |
7.50E-04 |
5.6675 |
633.96 |
197.12 |
Simulation Video - https://drive.google.com/file/d/1VY9YtHyE8OEwntm4OClgC-jIr3OhywuP/view?usp=sharing
Temperature:
|
Time [s] |
Minimum [°C] |
Maximum [°C] |
Average [°C] |
|
|
1 |
1.18E-38 |
19.85 |
22 |
21.473 |
|
2 |
3.75E-05 |
19.85 |
221.68 |
24.764 |
|
3 |
7.50E-05 |
19.85 |
300.33 |
28.25 |
|
4 |
1.13E-04 |
19.85 |
337.62 |
31.963 |
|
5 |
1.50E-04 |
19.85 |
360.85 |
35.252 |
|
6 |
1.88E-04 |
19.85 |
360.85 |
38.056 |
|
7 |
2.25E-04 |
19.85 |
360.85 |
40.882 |
|
8 |
2.63E-04 |
19.85 |
360.85 |
43.427 |
|
9 |
3.00E-04 |
19.85 |
360.85 |
46.208 |
|
10 |
3.38E-04 |
19.85 |
360.85 |
48.994 |
|
11 |
3.75E-04 |
19.85 |
360.85 |
51.765 |
|
12 |
4.13E-04 |
19.85 |
360.85 |
54.623 |
|
13 |
4.50E-04 |
19.85 |
360.85 |
57.327 |
|
14 |
4.88E-04 |
19.85 |
360.85 |
60.196 |
|
15 |
5.25E-04 |
19.85 |
360.85 |
62.911 |
|
16 |
5.63E-04 |
19.85 |
360.85 |
65.767 |
|
17 |
6.00E-04 |
19.85 |
360.85 |
68.415 |
|
18 |
6.38E-04 |
19.85 |
360.85 |
71.288 |
|
19 |
6.75E-04 |
19.85 |
360.85 |
73.998 |
|
20 |
7.13E-04 |
19.85 |
360.85 |
76.815 |
|
21 |
7.50E-04 |
19.85 |
360.85 |
79.675 |
Simulation Video - https://drive.google.com/file/d/1HdCaCjJm0P2xHFu-27o95Gcu_rvh6lnA/view?usp=sharing
Tabulation:
|
Cases |
Max. Total Deformation (mm) |
Max. Equivalent Stress (MPa) |
Max. Temperature (°C) |
|
Case 1 |
29.259 |
676.75 |
376.95 |
|
Case 2 |
20.796 |
674.38 |
360.85 |
Conclusion:
From the results, we can that if we reduce the velocity the Max. Total Deformation and Max. Temperature of the body reduces but the Max. Equivalent Stress of the body remains nearly the same.