Week 9 Machining with Planer Challenge

• Objective: Perform an explicit dynamics simulation to find out the Equivalent Stress, Total Deformation and also insert a User-defined result to calculate the temperature of the body. You need to perform this for 2 cases. One will be with a cutting velocity of 20000mm/s and the other will be with a cutting velocity of 15000mm/s.

Procedure:  Create an Explicit Dynamics analysis on ANSYS Workbench:

• Import Geometry:  We will import the given model into the system, we will check for any issues in the model with Spaceclaim. The below image shows the geometry.

• Assign Material: for this challenge, we will assign Steel 1006  from Explicit Material to the workpiece and  Structural Steel for Cutting Tool. Change the behavior of the tool to Rigid.

Steel 1006:

Structural Steel:

• Contact Set-Up: Here we will delete all the contacts generated and assigned to the model and only keep the Body Interaction.

• Mesh:  Here to mesh the model we will use two different methods for each part:

We will mesh the Cutting Tool with Tetrahedrons, we will select the Cutting Tool with body selection.

For Workpiece, we will mesh the part by using edges, we will select the 4 edges from any one side and then create a mesh by giving the number of divisions, as shown in the image below:

•  Analysis Settings and Boundary Conditions: For Analysis settings, we will give 7.5e-04 seconds as End Time. The end time is what defines the period for which each step will run. THe umber pf steps for this analysis will be one.

 

Velocity:  We will select the linear velocity of the Cutting Tool on Workpiece as 15000mm/s for one case and 20000mm/s for another,

Fixed Support: We will create fixed support so that Workpiece is not displaced during simulation:

• Results: 

Case 1: Velocity 15000mm/s

Equivalent Strain:

Total Deformation:

User-Defined Result: Temperature:

Case 2: Velocity 20000mm/s

Equivalent Strain:

Total Deformation:

User-Defined Result: Temperature:

• Conclusion: From the results above we can see tha with increased Velocity of Cutting Tool the more material was removed. Also, we can see that strain developed were lesser with higher Velocity, however with this we can see that deformation and temperature generated was also higher. Hence, for the Cutting Tool velocity can be decided based on Workpiece material and the operation to be performed.