# A Study of Fixture Layout and Clamping Force for a Ti-6Al-4V Disk in a Vertical Turning Lathe Numerically Controlled Machine Maureen Fang Sept 17, 2009.

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A Study of Fixture Layout and Clamping Force for a Ti-6Al-4V Disk in a Vertical Turning Lathe Numerically Controlled Machine Maureen Fang Sept 17, 2009

Overview Vertical Turning Lathe (VTL) Machine Fixture-Disk Assembly
Cutting Forces Finite Element Models in ANSYS Initial Fixture Layout Deflections within Disk Questions

Vertical Turning Lathe (VTL) Machine

Fixture-Disk Assembly
Inner Diameter=0.457m (18 in) Outer Diameter=0.508m (20 in) Height=0.0508m (2 in) Clamp Locator Plate

Machining an Outer Diameter
Cutting Tool

Cutting Forces Orientations

Cutting Forces Calculation Flow Diagram

Input Variables Tool Geometry Machining Parameters

Cutting Forces Tangential Force Orthogonal Cutting
Results are generated by Matlab codes for both oblique and orthogonal cutting Orthogonal cutting has only two cutting forces components Tangential force is the dominate component. Tangential Force Orthogonal Cutting

Finite Element Model in ANSYS
Number of elements 32000 Number of Nodes 38720 Degree of Freedom per Node 6 Type of Elements Brick Material of Workpiece Ti-6Al-4V Modulus of Elasticity 110 GPa Poisson Ratio 0.34

Clamps, Locators, and Cutting Forces applied to Initial Fixture Layout
Locators are constraint in 3 axis Clamping Force = 1500N

Deflections within a Finish Cut
The “U” shape curve presents the magnitude of deflection changes as the cutting tool travels from the top to the bottom surface of the disk. The displacement vector sum is largest at the top. The subsequent models will have the cutting forces applied at the top surface.

Key Locations to Represent a Dynamic Machining Process
ANSYS model is static analysis of a dynamic process. Therefore, selected cases are used to represent snap shots of the overall machining process. Point A, B, and C are key locations of disk where cutting forces have been applied, as disk rotates.

Displacement Vector Sum
B

Displacement Components
Z-component = axial direction Y-component = circumferential direction X-component = radial direction Clamp and locator is aligned with cutting forces at Key Location “B”

Contour Plots from ANSYS

Questions

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