Week 9 Machining with Planer Challenge

Aim-

We will have to 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. We 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-

• We have to first start as new project in the ansys workbench Select Explicit Dynamics and select the proper material for the workpiece.
• Here material has been specified in the project so we will select the material as mentioned.

For Workpiece-

For Cutting Tool-

• Now we have to import the model for that right click on the geometry tab and hit import>>then select the file from saved location and hit ok.

Connections-

• Here we dont define ady contact as it is not required so we will delete the existing contacts and keep body interactions.

Mesh-

First right click on the mesh>>insert>>method>>select whole component and select type as tetrahedrons for cutting tool.

• Now we have to createmesh for workpiece, to generate mesh, mesh>>insert>>sizing>>select four edges of workpiece and in type select the number of divisions as 10.

• Now generate the mesh.

Analysis Setting-

• Here we will give time step as 1e-3, refer below snap.

• Now insert a velocity boundry condition. to Cutting Tool, for case-1 we will give velocity as 20000mm/s and for case-2 give value of 15000mm/s.

Case-1

Case-2

• As workpiece is not going to move we will fix it at bottom.

Solution Setting-

• Here we have to define total deformation, to do so right click solution>>insert>>deformation>>Total.
• Now for stress right click on the solution>>insert>>stresses>>equivalent (von-Mises).
• For temperature, after solution went through deformation and stress, click on solution and click on worshit from home tab, scroll down and in that search for temperature and right click>>user defined result.

Results-

Total Deformation-

Case-1

Case-2

Equivalent Stress-

Case-1

Case-2

Temperature All-

Case-1

Case-2

Result Comparision-

Cases	Total Deformation (mm)		Equivalent Stress (MPa)		Temperature (0C)
	Min.	Max.	Min.	Max.	Min.	Max.
Case-1	0	46.69	7.44	660.7	19.85	373.77
Case-2	0	32.79	4.27	676.63	19.85	345.3

• From above table we can observe that the max deformation occurs in case -1 this is due to high cutting speed.
• Due to high speed and high material removal stress induced is less with high temperature increase in case-1.

Animated Results-

Case-1

Total Deformation-

Equivalent Stress-

Temperature-

Case-2

Total Deformation-

Equivalent Stress-

Temperature-

Conclusion-

• From above results we can see that as the speed increase the deformation rate increases as move material is being removed at high speed and also this leads to increase in temeprature.
• At low speed we observe high stress as speed is low here temperature rise is low as compared to case-1.
• So for cutting hard material it is always advisable to keep cutting speed low to achieve good surface finish.