Week 9 Machining with Planer Challenge

OBJECTIVE:

To perform an explicit dynamic analysis of a machining operation where the cutting tool propagates at a specified velocity along the length of the workpiece.The analysis is performed with 2 cases, the first one with a tool velocity of 20000mm/s and another with 15000mm/s.

The required results like the Equivalent Stress, Total Deformation, temperature are to be extracted

Procedure:

• Open ANSYS Work bench, from the analysis systems drop the Explicit Dynamics in Project schematic.
• Select required material from materials tab, we need Structural Steel for Cutting_Tool, and Steel 1006 for work piece.

Material properties of Structural Steel

Material properties of Steel 1006

• Import Geometry and open in design moduler to check the geometry. Open in Mechanical module and rename the parts as Work piece and cutting tool
• Change Cutting_Tool stiffness behaviour to Rigid.

• 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 use edge sizing and change type to no.of divisions as 10 and generate mesh as shown in below picture.

Analysis Settings:-

No.of Steps: 1
End Time: 7.5e-4
Maximum Number of Cycles:1e+07
Maximum Energy Error: 0.1 (for CASE_1) & 0.25 for (CASE_2)
Initial Time Step: Program Controlled
Minimum Time Step: Program Controlled
Maximum Time Step: Program Controlled

Boundary Conditions :-

• Fix Support (For CASE_1 & CASE_2):
• Keep bottom face of the Workpiece as a fixed.

• Velocity (For CASE_1):- 20000 mm/s.
• Apply velocity to Cutting_Tool in the positive X-Direction as given below:

• Velocity (For CASE_2):- 15000 mm/s.
• Apply velocity to Cutting_Tool in the positive X-Direction as given below:

• 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: 655.31 MPa

Total deformation: 32.328 mm

User Defined result for Temperature generated: 367.77^c

Case 2- Velocity 15000mm/s

Equivalent stress: 634.48 MPa

Total deformation:11.546 mm

User Defined result for Temperature generated: 364.74^c

Comparision of both cases

	Equivalent stress in MPA	Total deformation in mm	Temperature in ^c
Case - 1	655.31	32.328	367.77
Case - 2	634.48	11.546	364.74

CONCLUSION

From the above results we can observe that the equivalent stress, total deformation and temperature generated is high in case 1 compared to case2. It is quite obvious that this is due to the fact that the cutting tool velocity is higher in case 1 and with the end time being the same in both cases, By observing the above results, cutting tool velocity is directly proportional to result outputs.