Week 9 Machining with Planer Challenge

MACHINING WITH PLANER

OBJECTIVE

To perform an explicit dynamic Planer machining simulation in ANSYS Workbench and find out

• Total deformation
• Equivalent stress
• User defined result for temperature of the body

Analyse the model with two different velocities of 20000 mm/s and 15000 mm/s

MODEL SETUP

The 3D model of the setup is imported into ANSYS Space Claim. Check for any abnormalities in the Geometry.

MATERIAL ASSINGMENT:

• Structural steel is assigned to the Cutting Tool
• Steel 1006 is assigned to the Workpiece

The properties of materials used is shown below

• Structural Steel :

• Steel 1006 :

 

MODEL SETUP:

After importing the Geometry, rename the specimen and assign respective materials.

BODY INTERACTION

For all the bodies, Frictionless type Body interaction is chosen

MESHING:

The meshing is done as follows,

• The Cutting Tool is meshed with Tetrahedron elements with Patch Confirming Algorithm

• Edge sizing with 10 number of divisions is assigned to four vertical edges of the workpiece

FINAL MESH :

MESH DETAILS :

MESH QUALITY:

 

ANALYSIS SETTINGS:

 The simulation is run for 1 step.

The End time is assigned a value of 0.00075 s.

Other settings are default and as shown below

BOUNDARY CONDITIONS:

The boundary condition for this model are

• Case 1: Velocity of 20000 mm/s is assigned to the Cutting Tool in the X direction:

• Case 2: Velocity of 15000 mm/s is assigned to the Cutting Tool in the X direction:

• For Case 1 & 2: A Fixed support for the bottom face of the Workpiece:

 

RESULTS:

 

CASE 1 - Cutting velocity of 20000 mm/s:

ANIMATION FILE :

• Total Deformation

• Equivalent Stress

• User defined result for Temperature of the body

 

CASE 2 - Cutting velocity of 15000 mm/s:

ANIMATION FILE:

• Total Deformation

• Equivalent Stress

• User defined result for Temperature of the body

 

 CONCLUSION:

 

The values of all the results are tabulated below,

From the results, it can be inferred that

• Equivalent Stress increases when cutting velocity is decreased from 20000 mm/s to 15000 mm/s. As material can resist more load when velocity is decreased, stress induced is higher
• Total Deformation decreased when cutting velocity is decreased. When Velocity is decreased, Strain and deformation in the workpiece is reduced.
• Temperature generated remains almost constant for both the cases, with higher value in case 1. At higher velocities, large amount of material is removed in a short period of time and hence heat generated will be higher due to energy dissipation, so the temperature is higher when cutting velocity is increased.

The simulation files are attached below