Week 9 Machining with Planer Challenge

Machining with Planer Challenge

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 acutting velocity of 20000mm/s and the
Case-2
will be with a cutting velocity of 15000mm/s.

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. Aplaner is similar to a shaper, but larger, and with workpiece moving, whereas in a shaper the cutting tool moves.

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, whichcontains 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 Explicitmaterials and make tool behavior as rigid.

FIG 5: Material properties of a Steel 1006

7. Contacts- In this model we have a default Frictional contact.

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

9.Analysis settings, end time as 7.5e-4, maximum energy error as 0.1 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 plasticstrain and User defined result temperature of the body.

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

FIG13: Solver outputs

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

Total Deformation

Equivalent Elastic Strain

Equivalent Stress

 TEMPERATUREALL

CONCLUSION: