'Shrink Fit Analysis of Tool Holder' simulation project by ahmedhussain18


#1

I created a new simulation project called 'Shrink Fit Analysis of Tool Holder':

In this project the shrink fit analysis of tool holder is performed.


More of my public projects can be found here.


#2

Description


 
Ever wondered how a steel tire is fit around a wheel of a railway engine? Shrink-fitting. It is a method normally used to obtain an interference fit between two parts of a mechanical assembly. It is performed by either heating or cooling a part based on the type of fit. For instance, if one wants to join the outer diameter of a pipe to the internal diameter of a flange, one must either heat the pipe (expansion) or cool the flange (contraction).
 
A good shrink-fit has leaves a strong joint after both the parts reach the same temperature. Although, this isn’t always the case. Sometimes, the materials tend to warp or disfigure due to the thermal stress, leading to weak joints. A thermal analysis helps us analyze the behaviour of all the parts involved constructed from different materials.
 

Project Goals


 
This project is inspired by a common industrial practice that uses induction shrink fitting technology to preheat metal components, making them expand and allowing the insertion or removal of another component. In the current project, the shrink fitting of a tool holder is performed in order to fit a tool in it.
 

Geometry


 
The full model can be seen in the figure below. The tool holder lower portion is provided by Atley Wagner and used in post-processing afterwards.
 


 
 

Meshes


 
In order to save computational time and space, only the upper portion of the tool holder with a smaller tool size is used for the analysis. Furthermore, due to symmetry and availability of a cyclic symmetry boundary condition, only 1/36 th of the model was considered. The geometry used for the analysis is shown in the figure below. The light blue solid represents the tool holder.
 


 
The geometry is meshed using tetrahedralization with refinements whereas the contact region is further refined. The mesh is shown in figure below.
 

 

Simulations


 
A nonlinear, uncoupled thermomechanical transient analysis is performed. The cyclic symmetry is applied to both solids with a 10 degree angle. A physical Augmented Lagrangian contact is defined for the contact between two solids with fictitious clearance so that the contact will take place after the tool holder’s expansion. Furthermore, a bonded contact for heat transfer between the two solids is also defined. Next, the geometry is constrained in the x and y- direction to restrain symmetry.
 
The surface heat flux due to induction coil heating is applied to the red highlighted surface (shown in geometry figure above) for 6 seconds via a table uploaded onto the platform. Post applying a coil heating, the outer surfaces of the geometry is exposed to cold blown air for 12 seconds by applying a convective heat flux in order to fit the tool holder over the tool. This is also done by uploading a table onto the SimScale platform. The analysis is run on 4 cores and took about 120 minutes to complete.
 

Results and Conclusions


 
The figures below show the displacement, temperature, and von Mises contour plot at 6, 10 and 18 seconds respectively.
 


 

 

 
An interesting observation is the trend of the stress, which grows and relaxes over time when the tool holder is heated and then cooled down immediately. The graphs below show the maximum and minimum von Mises stress in the tool holder and tool respectively over time.
 

 

 
Finally, the animation of the performed simulation can be seen in the figures below for displacement, temperature, and von Mises stress respectively.
 
Note: The deformation was scaled 2 times in order to visualize the process more clearly.
 

 

 


#3

Very good job! Super cool :slight_smile:


#4

Thanks @jousefm! :smile:


#5

good Job

Can you help me to do like this


#6

Hi @sameh!

Simply copy the project and play with the settings to get familiar with the platform :slight_smile:

All the best!

Jousef