Finite Element Analysis of a CNC Milling Machine Vice and

Potential Modifications.

Phil Miller
 
 
 
Finite Element Analysis in Design – DP238
 
 
 
 
 Introduction
What is FEA? What is the problem?

Finite Element Analysis consists of using a I hoped to investigate a problem which related
computer model of a material or design that is to my degree so began looking at problems
stressed and analyzed for specific results. within engineering workshops.
 It is used in the development of new product Due to the nature of engineering workshops
design to check potential flaws and in existing there are many large and heavy pieces of
product refinement. machinery.
The system can place multiple loads of a A major component regulary used are machine
model to simulate real life situations that the vices, so I began to look at potentials
product could experience. improvements and investigate flaws within the
general design.
Milling Machine Vice
 Background Research
Research Topics Machine Vice Specification

• Types of machine vice Tilt Lock Machine Vice

• Materials (Grade of Casting) CRITERIA    
A Width of jaws (mm) 100
• Geometry B Depth of jaws (mm) 28
• Relevant British Standards C Width fixed base (mm)
Height of fixed base
180

• Determine resonable objectives D (mm) 57

E Overall length (mm) 290
F Tenon slot (mm) 5

This vice was selected due to the fact it is

regulary used within machine shops on milling
machines. The university has a model very
similar for me to use in my project.
Selected Model
 Objectives
• To gather relevant and useful information about a machine vices standard
design features (Material, Dimensions...Etc.)
• To have an understanding of the British standards relating to the vice and how
these effect its operation (Grade of casting, Geometry…Etc.)
• To have a greater understanding of the potential tests to be carried out of the
vice (Normal static study, Buckling, Fatigue, Failure analysis…Etc.)
• To carry out research for potential improvement to the machine vice (Material
suitability, Design, Geometry, Removal of material…Etc.)
• If possible, decrease the mass of the vice by 1Kg while not reducing the
rigidity by more than one percent.
 Meshing & Simulation

 FEA is a tool for performing engineering

 The software uses parameters to place
analysis. It includes the use of mesh
multiple loads such as force and pressure
generation techniques for dividing
onto the model, simulating a real life
a complex problem into small elements.
situations these are then calculated and
estimates are made regarding the models
reaction.
 Method
Analysis Potential Forces Produce Meshed Model

Free Body Diagram – This is a breakdown of The model as a whole had to be adjusted for a
all forces acting on the model and the reaction mesh to be completed.
forces expected to be produced. All parts of the assembly which were not
These figures were based on manufacturing appropriate were removed to make meshing
specification and manual calculation. possible.
 Method
Forces and Fixings Run Simulation

The forces acting on the jaws were taking for The simulation is run with all fixings and
the manufactures specification for maximum forces which are to be tested. Results can begin
load. to be collected and the model analysis can
The fixings represent the pressure acting on the begin.
vice being held to the machine bed.
 Collecting Results

M a x S tr e s s - V o n M i s e s (M P a )
All required simulations are run on the model.
The values can be collected and plotted.
Analysis on the mesh can be carried out and
plotted also.

Mesh Local Size (mm) Vs Max Stress - Von Mises (Mpa)

45
40
35
30
25
Mesh Local Size (mm) Max Stress - Von Mises (Mpa) 20
10 30 15
10
8 35 5
0
6 38 3 4 5 6 7 8 9 10 11

There is a collection4 of different stresses over 39 Mesh Local Size (mm)

different mesh sizes. The stresses recorded is

higher the smaller size of the mesh in the
model.
 Results

D isp la ce m e n t (m m )
The testing begins with trying to investigate
the rigidity of the model before and Applied Forces (kN) Vs Displacement (mm)
improvements can be made. 0.01
0.01
0.01
0.01
0
Total Force (kN) Displacement (mm) 0
0
5 0.0018
0
10 0.0036 0
4 6 8 10 12 14 16 18 20 22
15 0.0055 Total Applied Force (kN)
20 0.0073

The force is gradually increased over both jaws

and the displacement is recorded and plotted.
Although the displacement seems insignificant
when related to potential engineering
tolerances it could have a large effect.
 Potential Improvement
The research carried out on potential improvements showed that
there are different techniques to improve the distribution on load.
Improvements could have been made to the design through the
following methods:
• Coring
• Fillets on Mating Faces and Corners
• Reallocation of Load.
 References
WEBSITES:
• http://its.foxvalleytech.com/machshop3/basicmill/WorkHold.htm
• http://www.cnccookbook.com/CCMillTipsTechniques.htm (01/01/11 09:48)
• http://www.google.co.uk/patents?
hl=en&lr=&vid=USPAT3650522&id=UUA0AAAAEBAJ&oi=fnd&dq=machine+vice+&printsec=abstract#v=
onepage&q=machine%20vice&f=false (Mechanical Clamping Device : Patent Number – 3650522)
• http://www.google.co.uk/patents?
hl=en&lr=&vid=USPAT2667799&id=yWFnAAAAEBAJ&oi=fnd&dq=milling+machine+vice+british&prints
ec=abstract#v=onepage&q&f=false (Milling Vice Patent : Patent Number – 2667799)
• http://www.dapra.com/workholding/hydravise/specs.htm
• http://www.slideshare.net/roehmgmbh/rhm-vices
• http://grabcad.com/library/machine-vice--22
 http://www.sv.vt.edu/classes/MSE2094_NoteBook/97ClassProj/num/widas/history.html

BOOKS:
• Haan, E. R. "Selecting and using a bench vise"
• Winston A. Knight, Boothroyd Geoffrey. “Fundamentals of Metal Machining and Machine Tools, Third
Edition”
• “Zeus Precision Data Charts and References Tables for Drawing Office, Toolroom & Workshop”