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of another system, especially a computer program designed for that purpose
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Mass Minimization of Broaching Table
FEA Analysis for Moving Mass
FEA analysis of existing design
The original design was analyzed using Finite Element Analysis (FEA). It was observed that the factor of safety (FOS) in the current design was 8.15. Clearly it could be seen that the table is over designed with FOS more than double of that required.
Conclusion
Maximum stress of 1.9 Mpa is lower than tensile strength of 2.1 Mpa (The results are for four times the actual loading).
The Stress is reasonably well distributed along the section, this shows there is no stress concentration at any point and the solution is close to the optimum solution.
Objective
The vertical machining setup has a moving table while the tool is fixed. The objective of this project was to reduce the mass of the moving table so that minimum energy is used for its movement. In the process it shall be ensured that the moving table will withstand the huge loads it is subjected to during the metal cutting process . The new design shall be developed by removing material from redundant areas while taking care of manufacturing considerations.
Problem description
The original design of the table was quite bulky and weighed about 950 Kg. The material of the moving table was cast iron with tensile strength of 130 MPa. The table experiences loads up to 80 tonnage during the machining operation (the region of force application is shown by dark blue arrows in the meshing image alongside). The guiding holes do not allow the tilting of the table. The safe or working stress for cast iron for this kind of application was obtained from a material handbook and papers with similar studies. It was found that the minimum factor of safety (FOS) for this operation shall be 4.