Week 9 Machining with Planer Challenge
Introduction to Metal cutting:
A typical metal cutting process by single point cutting tool. In this process, a wedge shaped tool moves relative to the work piece at an angle a. As the tool makes contact with the metal, it exerts pressure on it. Due to the pressure exerted by the tool tip, metal will shear in the form of chips on the shear plane. A chip is produced ahead of the cutting tool by deforming and shearing the material continuously, along the shear plane.
Objective:
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.
Procedure:
* Open ANSYS Work bench, from the analysis systems drop the Explicit Dynamics in Project schematic.
* Select required material from materials tab, In our case-1 we need Structural Steel (Default) for cutting tool, and Steel 1006 for work piece.
* Import Geometry and open in design moduler to check the geometry. Open in Mechanical module and rename the parts (if required) for easy identification purpose.
* In the connections, delete default contacts. and keep the Body intraction as usual.
* Due to complex shape of tool, apply mesh method as tetragedrons and for work piece small edges use type as no.of divisions as 10 and generate mesh as shown in below picture.
* In the Analysis settings, enter end time as 7.5e-004s and remaining all the settings kepp as it is, hence history of previous operations.
* Insert velocity under Explicit dynamics and enter 20000mm/s in the x-axis, keep zero on remaining axis.
* Insert fixed support and fix the work piece by selecting the bottom surface.
* Insert out put results which we required to analyse, in our case we are going to find Equivalent stress, total deformation and user defined result to find out temperature.
* Click the solve to start the simulation.
Results: Case 1- Velocity 20000mm/s
Equivalent stress: 673.95 MPa
Total deformation: 34.312mm
User Defined result for Temperature generated: 367.77^c
* Case2- Cutiing tool velocity 15000mm/s
Equivalent stress:
Total Deformation:
User Defined result to find temperature:
| Velocity mm/s | Equivalent stress | Total Deformation | UDR, Temperature (C) |
| 20000 | 673.95 MPa | 34.312mm | 367.77 |
| 15000 | 634.35 MPa | 23.606mm | 364.74 |
Conclusion: By observing the above results, cutting tool velocity is directly proportional to result outputs.