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Maureen Fang Sept 17, 2009

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

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Maureen Fang Sept 17, 2009

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  1. 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

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

  3. Vertical Turning Lathe (VTL) Machine

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

  5. Machining an Outer Diameter Cutting Tool

  6. Cutting Forces Orientations

  7. Cutting Forces Calculation Flow Diagram

  8. Tool Geometry Machining Parameters Input Variables

  9. 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

  10. Finite Element Model in ANSYS

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

  12. 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.

  13. 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.

  14. Displacement Vector Sum C A B

  15. 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”

  16. Contour Plots from ANSYS

  17. Questions

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