Milling Simulation Help

  • Last Post 15 May 2019
dinler posted this 05 November 2018

Hello everybody,

My simulation is not working as intended. It is not removing any chip.

Details are below;

I defined two materials; a milling insert as Ceramic Insert Al203 and the workpiece as gray cast iron. Gray cast iron is defined as perfectly plastic.

I have defined friction between materials. Workpiece is fixed underneath. Insert has an angular velocity of 900 rpm and feed velocity of 0.03m/s.

I attach the archieve file and a screenshot showing the problem. Thank you all for your help.


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SandeepMedikonda posted this 05 November 2018

Dinler, Please post inline images of your setup, boundary conditions etc.

Not everyone on the community is able to download files.


dinler posted this 06 November 2018

Here it is. Insert deforms but does not machine the workpiece. 


SandeepMedikonda posted this 06 November 2018

Is it even moving and making contact as intended? 

Why is it developing deforming in the picture, is it just due to the inertial forces from Angular velocity?

Your boundary conditions are not being properly defined, use a constant velocity b.c as I show here and constrain all the other movements using the displacement boundary condition. In that post, I did it by constraining Z, where needed:


dinler posted this 13 November 2018


I redefined the boundary conditions as below and made it work, one minor problem though. I want the insert to rotate in a circular arc(I defined -900rpm on insert) however when 2 bodies collide, insert slowly slips in +x direction. Is there anyway that insert only rotates and follow the arc, and all 5 DOF's restricted like revolute joint.


SandeepMedikonda posted this 13 November 2018


You can always use a Remote Displacement to do this and try inserting an initial rotation velocity for the one degree of freedom that is not constrained.

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dinler posted this 16 November 2018

Dear SandeepMedikonda,


After changing velocity to angular velocity, It worked. Why it is not working with velocity though? Sorry if it is a newbie question. Thank you for your help.

edwardbastianh posted this 15 May 2019

Dear SandeepMedikonda

now, im doing the same simulation with ansys 19.0. i have a problem, that the chip formation is not formed. there's just red dots during the simulation. how do i get the chip formation for my simulation with ansys explicit dynamic. thank you

SandeepMedikonda posted this 15 May 2019

You might need to use a plastic material definition. Check what material model you are using? As a test try using AL 1100-O from the Engineering database. See if that helps.

If it doesn't please open a new discussion, describe your model with pictures, i.e., geometry, materials, boundary conditions and analysis settings.

You are more likely to get help when you open your own discussion. You can always link to any discussion or post using the #Permalink. Take a moment to review the Guidelines on the Student Community