Finite Element Numerical Simulation Analysis of Tool Strength

**1. Introduction** The metal cutting process involves the interaction between the cutting tool and the workpiece. In a machining system that includes machine tools, fixtures, tools, and workpieces, proper tool usage is crucial. The overall structure of the tool, its cutting edge material, and geometry directly affect tool life, machining quality, and production efficiency. Therefore, in the cutting process, the tool should possess high strength, good toughness, long service life, and favorable machinability. Conducting theoretical analysis on tool strength helps understand internal stress and strain states, which not only aids in selecting appropriate tools during machining but also provides a foundation for further improving tool performance and extending its lifespan. **2. Introduction to ANSYS Finite Element Analysis Software** ANSYS is a finite element numerical analysis software that integrates modern mathematical and mechanical theories with finite element techniques, computer graphics, and optimization methods. It features a comprehensive library of elements, material models, and solvers, making it suitable for various numerical simulations. This software efficiently solves structural dynamics, statics, linear, and nonlinear problems. As a leading CAE tool, ANSYS is widely used in engineering and has become one of the mainstream products in CAD/CAM/CAE software today. When analyzing the mechanical behavior of a structure using ANSYS, the software simulates applied loads to identify areas of stress and strain concentration, enabling strength analysis and design optimization. The three main steps in an ANSYS simulation are: creating a finite element model (preprocessing), applying loads and solving (solving), and visualizing the results (postprocessing). **3. Establishment of Tool Mechanical Model** During the metal cutting process, the force required to deform the material and form chips is called the cutting force. The magnitude of this force significantly influences the design and use of tools, machine tools, and fixtures. The cutting force consists of resistance from elastic and plastic deformation of the material, friction on the tool's rake face against the chip, and friction between the tool’s flank and the machined surface. To facilitate the analysis and measurement of cutting forces, a spatial rectangular coordinate system can be established based on the direction of the cutting speed, depth of cut, and feed direction. The total cutting force, Fr, is decomposed into three components: the main cutting force Fz (tangential force in the direction of cutting speed), the depth-of-cut resistance Fy (radial force), and the feed resistance Fx (axial force). These components help in understanding the forces acting on the tool during the cutting process. The main cutting force Fz is the largest component and serves as the primary basis for tool design and application. It is also used to evaluate the strength and stiffness of machine tool components and the motor power. The depth-of-cut resistance Fy does not consume power but affects the deformation of the system and machining accuracy. If the system rigidity is low, Fy may cause part deformation and vibration. The feed resistance Fx acts on the feed system and is critical for assessing the strength and rigidity of the feed mechanism. **4. Example of Tool Strength Finite Element Analysis** A turning tool is one of the most commonly used cutting tools, primarily used for machining rotating surfaces and end faces. The following example demonstrates the use of ANSYS for finite element analysis of tool strength. (1) **Test Parameters**: A carbide turning tool was used on a C630 lathe. The workpiece material was carbon steel. The tool geometry included an arbor made of 45 steel (B×H=20mm×25mm, L=150mm) and a blade made of YT15. Cutting parameters were: cutting speed vc = 100m/min, feed f = 0.5mm/r, and depth of cut ap = 2mm. The mechanical properties of the tool material were: tensile strength 600MPa, yield strength 355MPa, Young's modulus E = 206GPa, and Poisson’s ratio ν = 0.27. (2) **Mesh Division**: A solid finite element model of the turning tool was created in ANSYS. Using the self-adaptive meshing method, the tool was divided into 1569 nodes and 6934 elements. The mesh was denser in regions of stress concentration to provide clearer visualization. Assumptions were made, such as assuming linear elasticity and ignoring temperature effects. (3) **Simulation and Loading**: Based on experimental data and empirical formulas, the three components of the cutting force were calculated. The maximum load was applied at the tool tip, and constraints were applied at the tool's end to ensure accurate results. (4) **Result Analysis**: After the static load calculation, the stress distribution diagram, strain distribution diagram, and displacement contour map were obtained. The maximum stress occurred at the tool nose (node 21), with a value of 676MPa. The maximum strain was 0.00426m, and the maximum displacement was 0.609. These results indicate that the tool is within acceptable limits under the given conditions. Since the analysis was conducted under extreme conditions, the maximum stress slightly exceeded the yield limit but remained within the allowable range. For more accurate results, a nonlinear analysis could be performed. The tool tip, being the stress concentration point, is prone to failure. Therefore, using high-strength blade materials and adjusting cutting parameters are essential to maintain stable cutting conditions and ensure machining accuracy. **5. Conclusion** The application of ANSYS in finite element analysis provides an effective way to simulate and analyze tool strength. It allows for precise determination of stress and strain distribution, identification of critical points, and improvement of tool design and performance. This method offers a new approach to tool strength and life analysis, with significant practical value. The simulation method demonstrated in this paper can also be applied to other types of tools and components. For complex stress scenarios, nonlinear dynamic analysis can enhance the accuracy of results. Overall, ANSYS enables efficient and accurate strength analysis that traditional methods cannot achieve.

Cosmetic Bottle Lid

Cosmetic Bottle Lid is a key component of skin care packaging. It not only protects the products inside the bottle from external contamination, but also ensures the tightness and stability of the product. These caps are usually made of high-quality materials, such as plastic, metal or glass, to suit the preservation needs of different types of skin care products. By design, they may be equipped with sealing rings or special threaded structures to enhance the sealing effect and prevent product leakage or oxidation. In addition, some caps have innovative features such as built-in droppers or pump heads to provide a more convenient and hygienic use experience.

Cosmetic Bottle Lid,Cosmetic Bottle With Lid,Cosmetic Bottle Wholesale,Cosmetic Jars And Lids

Jiangyin Zem Packing Technology Co., Ltd. , https://www.zempackage.com