Milling simulation question

Hello all!

I would like to simulate a milling process for my thesis. It's almost already done, the material in case of the tool is titanium, and in case of the workpiece is a general steel. I used two Velocity to define the proper movements. The tool is rotating with 5000 [RPM], and the workpiece is moving forward with 34 [mm/s]. After the solution process I have got these results.

My question should be that how is this deformation value possible? I forgot to metion that the diameter of the tool is 10 [mm]. The average value of the total deformation is 5,33 [mm], I think it is to much. But the strain value looks good the average value is : 1,7 x 10(-4) mm. Then which query shows the right deformation of the tool?


Thank you in advance!

Answers

  • @Rekasi1996

    Deformation is the distance of the node from its starting point. Insert three Directional Deformations which measure the three signed components of distance of the node from its starting point. The values of Y will be close to zero. The values of X and Z will oscillate between +/- the radius of the tool depending on the angle of the tool since the start of the simulation.

  • Rekasi1996Rekasi1996 Member
    edited December 2020

    @peteroznewman

    First of all, thank you very much for your answer.

    To sum it up, in my case the total deformiation is not an interesting result, because the tool is rotating. I would like to get an average value of the deformation in case of the tool. How can I export those values of deformation which are not affected by the moving (tool diameter is 10 mm)?

    Here is the directional deformation in case of Z axis for example.

    Thank you in advance!

  • peteroznewmanpeteroznewman Member
    edited December 2020

    @Rekasi1996

    In CAD, is the tool centered on the Y axis? Does the tool have a vertex on the Y axis?

    If not, move the tool onto the Y axis and add a plane or two in CAD to split the edge or face to create a vertex at the center of the tool on the Y axis.

    Request output of that vertex of the signed Z deformation.

    Request output of that vertex of the signed X deformation.

    Those plots show the deflection of the tool tip while it is cutting.

  • @peteroznewman

    I can solve this problem with a new coordinate system. I defined one C.S. which is connected to the tool. The Y is equal with the axis of the tool.

    After that, I have defined a new Directional Deformation, with the new coordinate system.

    And it is almost good, because when the tool is moving than the coordinate system is following that. Is it possible that we define a coordinate system which is rotating with the tool? Because in this case the rotation not affects the deformation results. I tried to connect the coordinate system to the tool but I didnt find any good solution for that. It should be good if I get a deformation which are not affected by the rotation. I have to show this results in my thesis.

    Thanks for your help again! :)

  • @Rekasi1996

    Your image shows the Directional Deformation of the Body that has a maximum value of 10 mm. I suggested you select a Vertex at the tip of the tool, right on the Y axis. Did you do that? That vertex will have a zero output before cutting begins, and a very small output while cutting. Is that not sufficient for your needs?

    Try putting a Revolute Joint to Ground and scope it to the back circular face of the tool. That will put a Coordinate System on the Tool that rotates with the tool. Maybe you can Probe Joint Displacement under the Solution branch.

  • @peteroznewman

    I have tried your suggestion (vertex at tip of tool) and it works but I would like to shown the deformation for example along the edge of tool. I think your suggestion rather describe the buckling of the tool. Please correct me if I'm wrong. :)


    To be honest, I have tried your second idea of coordinate system topic. But in one case the simulate cannat solve, other case I cannot use those coordinate system which are created by joint to get the right deformations.


    Thanks again! :)

  • @Rekasi1996

    For the node on the Y-axis, I would not say it is for buckling. As the workpiece moves toward the tool, the cutting forces deflect the tool tip.

    I don't know if the joint idea will work, it was just something to try.

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