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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

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

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Vertical Turning Lathe (VTL) Machine

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

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Machining an Outer Diameter Cutting Tool

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Cutting Forces Orientations

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Cutting Forces Calculation Flow Diagram

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Input Variables Tool Geometry Machining Parameters

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Cutting Forces 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

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Finite Element Model in ANSYS Number of elements32000 Number of Nodes38720 Degree of Freedom per Node6 Type of ElementsBrick Material of Workpiece Ti-6Al- 4V Modulus of Elasticity110 GPa Poisson Ratio0.34

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

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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.

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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.

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Displacement Vector Sum A B C

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

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Contour Plots from ANSYS

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Questions

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