Puneet Final Semester Project

7/31/2019 Puneet Final Semester Project

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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



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


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


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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