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SSTTAATTIICC SSTTRREESSSS AANNAALLYYSSIISS OOFF AA LLAATTHHEE FFOORRMM TTOOOOLL
UUSSIINNGG AANNSSYYSS
Submitted in
Partial fulfillment for the award of the degree of
BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING
Submitted by-
Puneet Mehra (MT-1935-2K7)
Shubhra Kacker (MT-1947-2K7)
Shelly Tirlok (MT-1946-2K7)
Under the guidance of-
Mr. Mukesh Gupta
YMCA UNIVERSITY OF SCIENCE AND TECHNOLOGY FARIDABAD
SESSION 2007-2011
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CANDIDATES DECLARATION
I hereby certify that the work which is being presented in this project, entitled Static Stress
Analysis of a Lathe Form Tool using ANSYS, in partial fulfillment of the requirement for final
semester project and submitted in the Mechanical Engineering department is the authentic
record of our own work carried out during a period from January, 2011 to April, 2011 under the
supervision ofMr. Mukesh Gupta.
Puneet Mehra
Shubhra Kacker
Shelly Tirlok
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SUPERVISORS DECLARATION
This is to certify that the above statement made by the candidate is correct to the best of my
knowledge. All the four students were dedicated and sincere to their project work.
Mukesh Gupta
(Supervisor)
The Viva-Voice Examination of all the three Students has been held on..
Mukesh Gupta
(Supervisor)
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ABSTRACT
Simulation is now-a-days the best implemented method for the testing of materials and
products without actual prototyping which involves a lot of money and time which both are
very precious in the field of production.
On the other hand lathe is a very important tool used in day to day production which
uses various tools for different operations.
We have done a steady state stress analysis of a form tool used on lathe used for
making fillets and semicircular grooves for different stresses produced in it and also the strain
produced. For this purpose a HSS radius tool is used. All the values of the stresses and the
material properties were fed to a CAE package ANSYS v13 which implements FEM.
The results obtained were validated by the criteria of convergence and have been
produced in this report. The stress levels and the strain levels were very much within the
permissible limit and hence the tool is safe from the various forces acting on it
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ACKNOWLEDGEMENT
I am awed and overwhelmed as I bow to Dr. Sandeep Grover, Professor and Head, Department
of Mechanical Engineering Y.M.C.A. University of Science and Technology. I wish to express
my sincere gratitude to my project guide Mr. Mukesh Gupta, for providing me an opportunity
to do my project work Static Stress Analysis of a Lathe Form Tool using ANSYS. This project
bears on imprint of many people. It is an eternal honor to have word as his student for such a
long spell. His support, personal guidance, thought provoking discussions and encouragement
helped me guide through the upheavals. I wish God Almighty bestowed upon me the blessings
that I never falter in my duties as a true student.
Last but not the least I wish to avail myself of this opportunity, express a sense of gratitude and
love to my friends and my beloved parents for their manual support, strength and help for
everything.
Puneet Mehra
Shubhra Kacker
Shelly Tirlok
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CONTENTS
S.No. Description Page No.
Chapter 1: Introduction
1.1 What is Lathe? 9
1.2 Lathe History 9
1.3 Metal Working Lathe 11
1.4 Lathe Tools 13
1.5 Tool Materials 14
1.6 Tool Geometry 17
1.7 Metal Cutting 19
1.8 Forces in Two-Dimensional Cutting 20
1.9 ANSYS 22
Chapter 2: Literature Review
2.1 Previous studies in Stress Analysis of Tools 24
Chapter 3: Present Work
3.1 Tool Selection 27
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3.2 Selection of Tool Material 28
3.3 Structural Loads and Constraints 29
3.4 ANSYS Generated Project Report 30
Chapter 4: Results & Discussions
4.1 Results 44
4.2 Validation of Results 47
Chapter 5: Future Scope
5.1 Transient Structural 485.2 Thermal 485.3 Analytical Validation 49REFERENCES 50
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LIST OF FIGURES
S.No. Description Page No.
1.3 A Metal Working Lathe 12
1.4 Projections of a Lathe Tool 13
1.4 Types of Lathe Tools 14
1.6 Tool Bit Geometry 17
1.7 Machining Terminology 19
1.8 Forces in Metal Cutting 20
3.4 Tool Used 30
4.1 Maximum Principal Stress 44
4.1 Maximum Principal Elastic Strain 45
4.1 Total Deformation 46
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Chapter 1
INTRODUCTION
1.1What is Lathe?
A lathe is a machine tool which rotates the workpiece on its axis to perform various operations
such as cutting, sanding, knurling, drilling, or deformation with tools that are applied to the
workpiece to create an object which has symmetry about an axis of rotation.
Lathes are used in woodturning, metalworking, metal spinning, and glassworking. Lathes can be
used to shape pottery, the best-known design being the potter's wheel. Most suitably equipped
metalworking lathes can also be used to produce most solids of revolution, plane surfaces and
screw threads or helices. Ornamental lathes can produce three-dimensional solids of incredible
complexity. The material can be held in place by either one or two centers, at least one of which
can be moved horizontally to accommodate varying material lengths. Other workholding
methods include clamping the work about the axis of rotation using a chuck or collet, or to a
faceplate, using clamps or dogs.
1.2 Lathe History
The lathe is an ancient tool, dating at least to ancient Egypt and known and used in Assyria,
ancient Greece, and the Roman and Byzantine Empires.
The origin of turning dates to around 1300 BC when the Egyptians first developed a two-person
lathe. One person would turn the wood work piece with a rope while the other used a sharp
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tool to cut shapes in the wood. The Romans improved the Egyptian design with the addition of
a turning bow. Early bow lathes were also developed and used in Germany, France and Britain.
In the Middle Ages a pedal replaced hand-operated turning, freeing both the craftsman's hands
to hold the woodturning tools. The pedal was usually connected to a pole, often a straight-
grained sapling. The system today is called the "spring pole" lathe (see Pole lathe). Spring pole
lathes were in common use into the early 20th century. A two-person lathe, called a "great
lathe", allowed a piece to turn continuously (like today's power lathes). A master would cut the
wood while an apprentice turned the crank.
During the Industrial Revolution, mechanized power generated by water wheels or steam
engines was transmitted to the lathe via line shafting, allowing faster and easier work. The
design of lathes diverged between woodworking and metalworking to a greater extent than in
previous centuries. Metalworking lathes evolved into heavier machines with thicker, more rigid
parts. The application of lead screws, slide rests, and gearing produced commercially practical
screw-cutting lathes. Between the late 19th and mid-20th centuries, individual electric motors
at each lathe replaced line shafting as the power source. Beginning in the 1950s,
servomechanisms were applied to the control of lathes and other machine tools via numerical
control (NC), which often was coupled with computers to yield computerized numerical control
(CNC). Today manually controlled and CNC lathes coexist in the manufacturing industries.
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1.3 Metal Working Lathe
In a metalworking lathe, metal is removed from the workpiece using a hardened cutting tool,
which is usually fixed to a solid moveable mounting, either a toolpost or a turret, which is then
moved against the workpiece using handwheels and/or computer controlled motors. These
(cutting) tools come in a wide range of sizes and shapes depending upon their application.
Some common styles are diamond, round, square and triangular.
The toolpost is operated by leadscrews that can accurately position the tool in a variety of
planes. The toolpost may be driven manually or automatically to produce the roughing and
finishing cuts required to turn the workpiece to the desired shape and dimensions, or for
cutting threads, worm gears, etc. Cutting fluid may also be pumped to the cutting site to
provide cooling, lubrication and clearing of swarf from the workpiece. Some lathes may be
operated under control of a computer for mass production of parts (see "Computer Numerical
Control").
Manually controlled metalworking lathes are commonly provided with a variable ratio gear
train to drive the main leadscrew. This enables different thread pitches to be cut. On some
older lathes or more affordable new lathes, the gear trains are changed by swapping gears with
various numbers of teeth onto or off of the shafts, while more modern or expensive manually
controlled lathes have a quick change box to provide commonly used ratios by the operation of
a lever. CNC lathes use computers and servomechanisms to regulate the rates of movement.
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On manually controlled lathes, the thread pitches that can be cut are, in some ways,
determined by the pitch of the leadscrew: A lathe with a metric leadscrew will readily cut
metric threads (including BA), while one with an imperial leadscrew will readily cut imperial unit
based threads such as BSW or UTS (UNF,UNC). This limitation is not insurmountable, because a
127-tooth gear, called a transposing gear, is used to translate between metric and inch thread
pitches. However, this is optional equipment that many lathe owners do not own. It is also a
larger changewheel than the others, and on some lathes may be larger than the changewheel
mounting banjo is capable of mounting.
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1.4 Lathe Tools
The figure above shows a typical cutting tool and the terminology used to describe it. The
actual geometry varies with the type of work to be done. The standard cutting tool shapes are
shown below.
Facing tools are ground to provide clearance with a center. Roughing tools have a small side relief angle to leave more material to support the
cutting edge during deep cuts.
Finishing tools have a more rounded nose to provide a finer finish. Round nose tools arefor lighter turning. They have no back or side rake to permit cutting in either didection.
Left hand cutting tools are designed to cut best when traveling from left to right. Aluminum is cut best by specially shaped cutting tools (not shown) that are used with
the cutting edge slightly above center to reduce chatter.
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1.5 Tool Materials
Steel
Originally, all tool bits were made of high carbon tool steels with the appropriate
hardening and tempering. Since the introductions of high-speed steel (HSS) (early years
of the 20th century), sintered carbide (1930s), ceramic and diamond cutters, those
materials have gradually replaced the earlier kinds of tool steel in almost all cutting
applications. Most tool bits today are made of HSS, cobalt steel, or carbide.
High Carbon Tool Steel
Carbon steel, also called plain-carbon steel, is steel where the main alloying
constituent is carbon. The American Iron and Steel Institute (AISI) defines carbon
steel as: "Steel is considered to be carbon steel when no minimum content is
specified or required for chromium, cobalt, columbium, molybdenum, nickel,
titanium, tungsten, vanadium or zirconium, or any other element to be added to
obtain a desired alloying effect; when the specified minimum for copper does
not exceed 0.40 percent; or when the maximum content specified for any of the
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following elements does not exceed the percentages noted: manganese 1.65,
silicon 0.60, copper 0.60."
The term "carbon steel" may also be used in reference to steel which is not
stainless steel; in this use carbon steel may include alloy steels.
As the carbon content rises, steel has the ability to become harder and stronger
through heat treating, but this also makes it less ductile. Regardless of the heat
treatment, a higher carbon content reduces weldability. In carbon steels, the
higher carbon content lowers the melting point.
High Speed Steel
High speed steel (HSS or HS) is a subset of tool steels, usually used in tool bits
and cutting tools. It is often used in power saw blades and drill bits. It is superior
to the older high carbon steel tools used extensively through the 1940s in that it
can withstand higher temperatures without losing its temper (hardness). This
property allows HSS to cut faster than high carbon steel, hence the name high
speed steel. At room temperature, in their generally recommended heat
treatment, HSS grades generally display high hardness (above HRC60) and a high
abrasion resistance (generally linked to tungsten content often used in HSS)
compared to common carbon and tool steels.
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Alloying compositions of common high speed steel grades (by %wt)
Grade C Cr Mo W V Co Mn Si
T1 0.65-0.80 3.75-4.00 - 17.25-18.75 0.9-1.3 - 0.1-0.4 0.20
M2 0.95 5.0 5.0 6.0 2.0 - - -
M7 1.0 8.7 1.6 1.6 2.0 - - -
M35 0.94 4.1 5.0 6.0 2.0 5.0 - -
M42 1.10 3.8 9.5 1.5 1.2 8.0 - -
Carbides & Ceramics
Carbide, ceramics (such as cubic boron nitride) and diamond, having higher hardness
than HSS, all allow faster material removal than HSS in most cases. Because these
materials are more expensive and brittler than steel, typically the body of the cutting
tool is made of steel, and a small cutting edge made of the harder material is attached.
The cutting edge is usually either screwed on (in this case it is called an insert), or brazed
on to a steel shank (this is usually only done for carbide).
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1.6 Tool Geometry
Back Rake is to help control the direction of the chip, which naturally curves into the work due
to the difference in length from the outer and inner parts of the cut. It also helps counteract the
pressure against the tool from the work by pulling the tool into the work.
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Side Rake along with back rake controls the chip flow and partly counteracts the resistance of
the work to the movement of the cutter and can be optimized to suit the particular material
being cut. Brass for example requires a back and side rake of 0 degrees while aluminum uses a
back rake of 35 degrees and a side rake of 15 degrees.
Nose Radius makes the finish of the cut smoother as it can overlap the previous cut and
eliminate the peaks and valleys that a pointed tool produces. Having a radius also strengthens
the tip, a sharp point being quite fragile.
All the other angles are for clearance in order that no part of the tool besides the actual cutting
edge can touch the work. The front clearance angle is usually 8 degrees while the side clearance
angle is 10-15 degrees and partly depends on the rate of feed expected.
Minimum angles which do the job required are advisable because the tool gets weaker as the
edge gets keener due to the lessening support behind the edge and the reduced ability to
absorb heat generated by cutting.
The Rake angles on the top of the tool need not be precise in order to cut but to cut efficiently
there will be an optimum angle for back and side rake.
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1.7 Metal Cutting
Machining Terminology
Speed surface cutting speed (v)
Feed advance of tool through the part
Depth of cut depth of tool into part
Rake facetools leading edge
Rake angleslant angle of tools leading edge ()
Flank following edge of cutting tool
Relief angleangle of tools following edge above part surface
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1.8 Forces in Two-Dimensional Cutting
Cutting force, Fc
Thrust force, Ft
Fc and Ft produce resultant force R
R can be resolved into two components on tool face
Friction force, F = R sin
Normal force, N = R cos
= F/N
R is balanced by shear force, Fs, and a normal force, Fn, along the shear plane
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to = feed (f)
w = depth of cut (d)
Ff = Ft
Feed force = Thrust force
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1.9 ANSYS
Structural mechanics solutions from ANSYS provide the ability to simulate every structural
aspect of a product, including linear static analyses that simply provides stresses or
deformations, modal analysis that determines vibration characteristics, through to advanced
transient nonlinear phenomena involving dynamic effects and complex behaviors.
All users, from designers to advanced experts, can benefit from ANSYS structural mechanics
solutions. The fidelity of the results is achieved through the wide variety of material models
available, the quality of the elements library, the robustness of the solution algorithms, and the
ability to model every product from single parts to very complex assemblies with hundreds
of components interacting through contacts or relative motions.
ANSYS structural mechanics solutions also offer unparalleled ease of use to help product
developers focus on the most important part of the simulation process understanding the
results and the impact of design variations on the model.
Workbench PlatformThe ANSYS Workbench platform is the framework upon which the industrys broadest
and deepest suite of advanced engineering simulation technology is built. An innovative
project schematic view ties together the entire simulation process, guiding the user
through even complex multiphysics analyses with drag-and-drop simplicity. With bi-
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directional CAD connectivity, powerful highly-automated meshing, a project-level
update mechanism, pervasive parameter management and integrated optimization
tools, the ANSYS Workbench platform delivers unprecedented productivity, enabling
Simulation Driven Product Development.
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Chapter 2
LITERATURE REVIEW
It is a common practice now-a-days to simulate a situation of a part and various tests are done
before the actual manufacture of the protype.
It is done on various CAE packages implementing FEM like ANSYS, ABAQUS, NASTRAN, etc.
2.1 Previous studies in Stress Analysis of Tools
Abdullah Kurt [1] His study covers two main subjects: (i) The experimental and theoretical
analysis: the cutting forces and indirectly cutting tool stresses, affecting the cutting tool life
during machining in metal cutting, are one of very important parameters to be necessarily
known to select the economical cutting conditions and to mount the workpiece on machine
tools securely. In this paper, the cutting tool stresses (normal, shear and von Mises) in
machining of nickel-based super alloy Inconel 718 have been investigated in respect of the
variations in the cutting parameters (cutting speed, feed rate and depth of cut). The cutting
forces were measured by a series of experimental measurements and the stress distributions
on the cutting tool were analysed by means of the finite element method (FEM) using ANSYS
software. ANSYS stress results showed that in point of the cutting tool wear, especially from
von Mises stress distributions, the ceramic cutting insert may be possible worn at the distance
equal to the depth of cut on the base cutting edge of the cutting tool. Thence, this wear mode
will be almost such as the notch wear, and the flank wear on the base cutting edge and grooves
in relief face. In terms of the cost of the process of machining, the cutting speed and the feed
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rate values must be chosen between 225 and 400 m/min, and 0.1 and 0.125 mm/rev,
respectively. (ii) The mathematical modelling analysis: the use of artificial neural network (ANN)
has been proposed to determine the cutting tool stresses in machining of Inconel 718 as
analytic formulas based on working parameters. The best fitting set was obtained with ten
neurons in the hidden-layer using back propagation algorithm. After training, it was found the
R2 values are closely 1.
Mohamed N.A. Nasr & M.A. Elbestawi [2] provided the following study.
Tool-edge geometry has significant effects on the cutting process, as it affects cutting forces,
stresses, temperatures, deformation zone, and surface integrity. An Arbitrary-Lagrangian
Eulerian (A.L.E.) finite element model is presented here to simulate the effects of cutting-edge
radius on residual stresses (R.S.) when orthogonal dry cutting austenitic stainless steel AISI 316L
with continuous chip formation. Four radii were simulated starting with a sharp edge, with a
finite radius, and up to a value equal to the uncut chip thickness. Residual stress profiles started
with surface tensile stresses then turned to be compressive at about 140 m from the surface;
the same trend was found experimentally. Larger edge radius induced higher R.S. in both the
tensile and compressive regions, while it had almost no effect on the thickness of tensile layer
and pushed the maximum compressive stresses deeper into the workpiece. A stagnation zone
was clearly observed when using non-sharp tools and its size increased with edge radius. The
distance between the stagnation-zone tip and the machined surface increased with edge
radius, which explained the increase in material plastic deformation, and compressive R.S.
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when using larger edge radius. Workpiece temperatures increased with edge radius; this is
attributed to the increase in friction heat generation as the contact area between the tool edge
and workpiece increases. Consequently, higher tensile R.S. were induced in the near-surface
layer. The low thermal conductivity of AISI 316L restricted the effect of friction heat to the near-
surface layer; therefore, the thickness of tensile layer was not affected.
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Chapter 3
PRESENT WORK
3.1 Tool Selection
The radius tool used on a lathe machine is much different than a single point tool because as
the depth of cut increases the area under contact with the workpiece also increases. So the
contact area changes at each and every instant of time. So we selected this tool geometry to
focus our concentration to a different kind of geometry.
We have used a R4.5mm tool used for making a fillet of 4.5R.Tool length is 85mm.Flank length is 12 mm.Tool has a square cross section of 10mmx10mm.Clearance angle is 5o.Back rake angle is also taken as 5o.
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3.2 Selection of Tool Material
We have used High Speed Steel of T1 grade. It is the most widely used tool material in our workshop. Its consumption can be seen from the following table.
Grade C Cr Mo W V Co Mn Si
T1 0.65-0.80 3.75-4.00 - 17.25-18.75 0.9-1.3 - 0.1-0.4 0.20
M2 0.95 5.0 5.0 6.0 2.0 - - -
M7 1.0 8.7 1.6 1.6 2.0 - - -
M35 0.94 4.1 5.0 6.0 2.0 5.0 - -
M42 1.10 3.8 9.5 1.5 1.2 8.0 - -
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3.3 Structural Loads and Constraints
Analysis is steady state type. Load perpendicular to rake face = 800N. Load along the rake face = 1800N. 1/9th length of face and the base are constrained in all 3 directions as in a tool post. Analysis is done at 25 degree Celsius.
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Project
First Saved Tuesday, April 05, 2011
Last Saved Thursday, April 28, 2011
Product Version 13.0 Release
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Contents
Units Model (A4)
o Geometry Solid
o Coordinate Systemso Mesh
Mesh Controlso Static Structural (A5)
Analysis Settings Loads Solution (A6)
Solution Information Results
Material Datao high speed steel
Units
TABLE 1
Unit System Metric (m, kg, N, s, V, A) Degrees rad/s Celsius
Angle Degrees
Rotational Velocity rad/s
Temperature Celsius
Model (A4)
Geometry
TABLE 2
Model (A4) > Geometry
Object Name Geometry
State Fully Defined
Definition
Source C:\Users\Puneet\Desktop\project_files\dp0\SYS-4\DM\SYS-4.agdb
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Type DesignModeler
Length Unit Millimeters
Element Control Program Controlled
Display Style Part Color
Bounding Box
Length X 8.45e-002 m
Length Y 1.e-002 m
Length Z 1.e-002 m
Properties
Volume 8.1607e-006 m
Mass 6.6918e-002 kg
Scale Factor Value 1.
Statistics
Bodies 1
Active Bodies 1
Nodes 113916
Elements 78806
Mesh Metric None
Preferences
Parameter Processing Yes
Personal Parameter Key DS
CAD Attribute Transfer No
Named Selection Processing No
Material Properties Transfer No
CAD Associativity Yes
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Import Coordinate Systems No
Reader Save Part File No
Import Using Instances Yes
Do Smart Update No
Attach File Via Temp File Yes
Temporary Directory C:\Users\Puneet\AppData\Local\Temp
Analysis Type 3-D
Enclosure and Symmetry Processing Yes
TABLE 3
Model (A4) > Geometry > Parts
Object Name Solid
State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No
Stiffness Behavior Flexible
Coordinate System Default Coordinate System
Reference Temperature By Environment
Material
Assignment high speed steel
Nonlinear Effects Yes
Thermal Strain Effects Yes
Bounding Box
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Length X 8.45e-002 m
Length Y 1.e-002 m
Length Z 1.e-002 m
Properties
Volume 8.1607e-006 m
Mass 6.6918e-002 kg
Centroid X -3.9128e-002 m
Centroid Y 2.1397e-007 m
Centroid Z -1.4488e-005 m
Moment of Inertia Ip1 1.0958e-006 kgm
Moment of Inertia Ip2 3.8049e-005 kgm
Moment of Inertia Ip3 3.8041e-005 kgm
Statistics
Nodes 113916
Elements 78806
Mesh Metric None
Coordinate Systems
TABLE 4
Model (A4) > Coordinate Systems > Coordinate System
Object Name Global Coordinate System
State Fully Defined
Definition
Type Cartesian
Coordinate System ID 0.
Origin
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Origin X 0. m
Origin Y 0. m
Origin Z 0. m
Directional Vectors
X Axis Data [ 1. 0. 0. ]
Y Axis Data [ 0. 1. 0. ]
Z Axis Data [ 0. 0. 1. ]
Mesh
TABLE 5Model (A4) > Mesh
Object Name Mesh
State Solved
Defaults
Physics Preference Mechanical
Relevance 0
Sizing
Use Advanced Size Function Off
Relevance Center Coarse
Element Size Default
Initial Size Seed Active Assembly
Smoothing Medium
Transition Fast
Span Angle Center Coarse
Minimum Edge Length 6.2567e-004 m
Inflation
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Use Automatic Inflation None
Inflation Option Smooth Transition
Transition Ratio 0.272
Maximum Layers 5
Growth Rate 1.2
Inflation Algorithm Pre
View Advanced Options No
Advanced
Shape Checking Standard Mechanical
Element Midside Nodes Program Controlled
Straight Sided Elements No
Number of Retries Default (4)
Extra Retries For Assembly Yes
Rigid Body Behavior Dimensionally Reduced
Mesh Morphing Disabled
Defeaturing
Pinch Tolerance Please Define
Generate Pinch on Refresh No
Automatic Mesh Based Defeaturing On
Defeaturing Tolerance Default
Statistics
Nodes 113916
Elements 78806
Mesh Metric None
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TABLE 6
Model (A4) > Mesh > Mesh Controls
Object Name Body Sizing Refinement
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 1 Body 2 Faces
Definition
Suppressed No
Type Element Size
Element Size 1.e-003 m
Behavior Soft
Refinement 1
Static Structural (A5)
TABLE 7
Model (A4) > Analysis
Object Name Static Structural (A5)
State Solved
Definition
Physics Type Structural
Analysis Type Static Structural
Solver Target Mechanical APDL
Options
Environment Temperature 25. C
Generate Input Only No
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TABLE 8
Model (A4) > Static Structural (A5) > Analysis Settings
Object Name Analysis Settings
State Fully Defined
Step Controls
Number Of Steps 1.
Current Step Number 1.
Step End Time 1. s
Auto Time Stepping Program Controlled
Solver Controls
Solver Type Program Controlled
Weak Springs Program Controlled
Large Deflection Off
Inertia Relief Off
Restart Controls
Generate Restart Points Program Controlled
Retain Files After Full Solve No
Nonlinear Controls
Force Convergence Program Controlled
Moment Convergence Program Controlled
Displacement Convergence Program Controlled
Rotation Convergence Program Controlled
Line Search Program Controlled
Stabilization Off
Output Controls
Calculate Stress Yes
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Calculate Strain Yes
Calculate Contact No
Calculate Results At All Time Points
Analysis Data Management
Solver Files Directory C:\Users\Puneet\Desktop\project_files\dp0\SYS-4\MECH\
Future Analysis None
Scratch Solver Files Directory
Save MAPDL db No
Delete Unneeded Files Yes
Nonlinear Solution No
Solver Units Active System
Solver Unit System mks
TABLE 9
Model (A4) > Static Structural (A5) > Loads
Object Name Force Force 2 Fixed Support Fixed Support 2
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 1 Edge 1 Face
Definition
Type Force Fixed Support
Define By Vector
Magnitude 1000. N (ramped) 2000. N (ramped)
Direction Defined
Suppressed No
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FIGURE 1
Model (A4) > Static Structural (A5) > Force
FIGURE 2
Model (A4) > Static Structural (A5) > Force 2
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Solution (A6)
TABLE 10
Model (A4) > Static Structural (A5) > Solution
Object Name Solution (A6)
State Solved
Adaptive Mesh Refinement
Max Refinement Loops 1.
Refinement Depth 2.
Information
Status Done
TABLE 11
Model (A4) > Static Structural (A5) > Solution (A6) > Solution Information
Object Name Solution Information
State Solved
Solution Information
Solution Output Solver Output
Newton-Raphson Residuals 0
Update Interval 2.5 s
Display Points All
TABLE 12
Model (A4) > Static Structural (A5) > Solution (A6) > Results
Object Name Maximum Principal Elastic Strain Maximum Principal Stress Total Deformation
State Solved
Scope
Scoping Method Geometry Selection
Geometry All Bodies
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Definition
Type Maximum Principal Elastic Strain Maximum Principal Stress Total Deformation
By Time
Display Time Last
Calculate Time History Yes
Identifier
Integration Point Results
Display Option Averaged
Results
Minimum -6.9331e-008 m/m -1.1861e+008 Pa 0. m
Maximum 6.0645e-003 m/m 8.7878e+008 Pa 1.1047e-005 m
Information
Time 1. s
Load Step 1
Substep 1
Iteration Number 1
Material Data
High speed steel
TABLE 13
high speed steel > Constants
Density 8200 kg m^-3
TABLE 14
high speed steel > Isotropic Elasticity
Temperature C Young's Modulus Pa Poisson's Ratio Bulk Modulus Pa Shear Modulus Pa
25 2.25e+011 0.29 1.7857e+011 8.7209e+010
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TABLE 15
high speed steel > Tensile Yield Strength
Tensile Yield Strength Pa
2.2e+009
TABLE 16
high speed steel > Compressive Yield Strength
Compressive Yield Strength Pa
2.2e+009
TABLE 17
high speed steel > Tensile Ultimate Strength
Tensile Ultimate Strength Pa
2.4e+009
Table 3.2 Material Specification
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Chapter 4
RESULTS AND DISCUSSION
4.1Results4.1.1 Maximum Principal Stress
Maximum stress = 8.5953E+008 Pa. Minimum stress = -8.7402E+007 Pa.
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4.1.2 Maximum Principal Strain
Maximum strain = 6.2275E-003 m/m. Minimum strain = 7.9345E-012 m/m.
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4.1.3 Total Deformation
Maximum = 1.1047e-005 m. Minimum = 0 m.
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4.2 Validation of Results
Criterion of convergence has been applied.
The results converge to a similar value when input is varied in a similar fashion.
This shows that the results obtain from the simulation are valid.
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Chapter 5
FUTURE SCOPE
Simulation is a safe and time saving process which can be applied to almost any known product
on earth. It saves precious time and money and thuscan be used in a number of ways to
optimize the product without actual prototyping.
Types of analysis systems
Transient Steady state Modal Structural
Thermal
5.1 Transient Structural
Future work can include the transient analysis of the tool considering the feed, speed, depth of
cut, etc. and other cutting parameters like work material and so on.
5.2 Thermal
When the temperature factor is considered the temperature gradient is considered and also
the effect of temperature on the tool is considered and thus can be a part of future scope.
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5.3 Analytical Validation
The result validation can also be done by solving the tool geometry for the different loads,
constraints or boundary conditions analytically. This involves complex calculations and a very in
depth knowledge on FEM which is out of our scope at this point of time and thus comes under
the future scope of the project.
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REFERENCES
Wikipedia
Google Books
www.scribed.comwww.matweb.comwww.makeitfrom.com [1] Abdullah Kurt work on Modelling of the cutting tool stresses in machining of Inconel 718
using artificial neural networks , Gazi University, Technical Education Faculty, Mechanical
Education Department, Turkey.
[2] Work on Modelling the effects of tool -edge radius on residual stresses when orthogonalcutting AISI 316L by Mohamed N.A. Nasr & M.A. Elbestawi, McMaster University, Hamilton,
Ontario, Canada
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