Week 9 Machining with Planer Challenge

Aim of the project:

To perform the Explicit dynamics simulation for the given workpiece and tool Planar machining model Capture Total deformation, Equivalent stress, and temperature.

Compare the results in varied condition of Cutting velocity in case 1 it should be 20000mm/s and case 2 it is 15000mm/s.

Set Up

1. In the Ansys workbench we chose Explicit dynamics and in engineering data we added the material Steel1006.
2. After Importing the Specimen model in the Geometry, we opened it in SpceClaim and checked for any abnormalities.
3. Once we opened the Specimen model in Mechanical module, we renamed it and assigned Steel 1006 material to the workpiece and changed stiffness behavior as rigid for Cutting tool.
4. We have deleted the existing Bonded contacts and kept body interactions as it is under connections.
5. In the meshing we used tetrahedron for Cutting tool and Edge sizing for Workpiece.

6. In analysis settings we kept all data as it is except End time and added 7.5e-4 as end time.
7. We have added velocity to the cutting tool For the case 1 we kept 20,000mm/s in X Direction.
8. We have arrested the bottom surface of workpiece with Fixed support.
9. Finally, we requested for desired solutions and got the results as shown below.

Total deformation : - Maximum : 25.706 mm

Equivalent Elastic strain

Maximum: 2.1902 mm/mm

Equivalent Elastic stress

Maximum: 492.62 MPa

Temperature

Maximum : 376.95 °C

Case: 2

In case 2 we have changed the velocity of the cutting tool to 15000mm/s

We have requested for simulation results once again and got the same as shown below.

Directional deformation : - Maximum : 20.303 mm

Equivalent Elastic strain

Maximum: 2.3588 mm/mm

Equivalent Elastic stress

Maximum: 635.87 MPa

Temperature

Maximum : 363.51 °C

Conclusion

Velocity	Directional Deformation (Max.)	Max. Von-mises Stress (Mpa)	Temperature (Degrees)
20,000mm/s	25.706 mm	492.62 MPa	376.95 °C
15,000 mm/s	20.303 mm	635.87 MPa	363.51 °C

We observed that Stress increased when velocity of cutting tool reduced. But temperature was more in case of more velocity.