Week 9 Machining with Planer Challenge

Machining with Planer

OBJECTIVE: The main objective of this challenge is to perform an explicit dynamics simulation of machining with planer, and to find out the Equivalent Stress, Total Deformation and also to insert a User defined result to calculate the temperature of the body. We need to perform this for 2 cases. Case-1 will be with a cutting velocity of 20000mm/s and the Case-2 will be with a cutting velocity of 15000mm/s.

SOFTWARE USED: ANSYS Workbench 2021 R1 and ANSYS Mechanical for Analysis.

INTRODUCTION:

A planer is a type of metalworking machine tool that uses linear relative motion between the workpiece and a single-point cutting tool to cut the work piece. A planer is similar to a shaper, but larger, and with workpiece moving, whereas in a shaper the cutting tool moves.

Fig.1: Working principle of machining with planer

FIG.2: CAD MODEL

PROCEDURE:

1. Open the ANSYS Workbench software. Under the Analysis system select the Explicit dynamics and wait for few seconds to pop up the window, which contains Engineering data, Geometry, Model, setup, Solution and Results.

2. Rename the Explicit dynamics as Machining with Planer.

3. Under geometry import the Machining with Planer model.

4. Update the model by right click and edit the Model for Preprocessing.

5. Wait for few seconds and ANSYS Mechanical will open as shown below. Rename the model as work piece and cutting tool.

FIG.3: CAD model of Long Piston model.

6. Assign the material to the model. Default we have structural steel and assign Steel 1006 material to the workpiece, by selecting the material under Explicit materials and make tool behavior as rigid.

FIG 4: Material properties of a Structural Steel

FIG 5: Material properties of a Steel 1006

7. Contacts- In this model we have a default bonded contact. So delete that bonded contact and under body interactions make sure that the body interaction type as frictionless.

8. In ANSYS automatic mesh will be performed with Default mesh size and so insert the method and select the tool, change the method as tetrahedrans. Select the sizing option and select the four edges as shown below and assign the no. of division as 10. Then generate mesh.

FIG 6: Method selection

FIG 7: Edge selection

FIG 8:Meshing

Fig.9: Element Quality

9. Analysis settings, end time as 7.5e-4, maximum energy as 2 and remaining settings are default.

FIG 10: Analysis settings

10. Insert a velocity select the cutting tool and assign the values as shown below.

For Case-1: X=20000mm/s, Y=0 and Z=0.

For Case-2: X=15000mm/s, Y=0 and Z=0.

Fig.11: Velocity

11. Insert a fixed support to the work piece and select the face as shown below.

Fig.12: Fixed support

12. Now request for the outputs such as equivalent stress, equivalent elastic strain, directional deformation in x-Direction, total deformation, equivalent plastic strain and User defined result temperature of the body.

13. SOLVE the solution and we can see the simulation run under soluion information.

FIG13: Solver output

Fig.14: Energy Conservation

Fig.15: Momentum Summary

Fig.16: Energy Summary

SIMULATION RESULT:

CASE-1: With a velocity of 20000mm/s.

Fig 17: Equivalent Stress

Fig 18: Equivalent Elastic Strain

Fig 19: Equivalent Plastic Strain

Fig 20: Total Deformation

FIG: 21 DIRECTIONAL DEFORMATION (X-Axis)

FIG: 22 Temperature

CASE-2: With a velocity of 15000mm/s.

Fig 23: Equivalent Stress

Fig 24: Equivalent Elastic Strain

Fig 25: Equivalent Plastic Strain

Fig 26: Total Deformation

FIG: 27 DIRECTIONAL DEFORMATION (X-Axis)

FIG: 28 Temperature

Camparism of results:

CASES	Equivalent Stress (MPa)	Equivalent Elastic Strain	Equivalent Plastic Strain	Total Deformation (mm)	Directional Deformation (X-Axis) (mm)	Temperature (°C)
1.	Max: 698.11 Min: 0	Max: 0.0034569 Min: 0	Max: 1.4462 Min: 0	Max: 12.541 Min: 0	Max: 12.346 Min: -4.3867	Max: 313.82 Min: -27.493
2.	Max: 697.52 Min: 0	Max: 0.0034033 Min: 0	Max: 1.4969 Min: 0	Max: 11.65 Min: 0	Max: 8.6606 Min: -6.2073	Max: 309.77 Min: -35.664

CONCLUSION:

From the above result we can conclude that the Maximum equivalent stress of 698.11MPa is experienced in case-1 and Maximum equivalent stress of 697.52MPa is experienced in case-2. So the change in velocity will not effect the stress values so much. The Equivalent Elastic Strain is also close to each other. The equivalent plastic strain of 1.4969 is high in case-2. The Max temperature of 313.82°C is experienced in case-1 and the Max temperature of 309.77°C is experienced in case-2. The Max Total Deformation of 12.541mm is experienced in case-1 and the Max Total Deformation of 11.65mm is experienced in case-2. So finally we conclude that case-1 will have smooth and good surface finish than the case-2. By this we can say that the if velocity is higher then we get smooth and good surface finish.

LINK: https://drive.google.com/drive/folders/1jx4dlcfyeTEv3eewk8pvzLL2J4ErbOBp?usp=sharing