The following ANSYS parametric file is meant for simulating the machining process as explained in chapter 6.0. The following recommendations should be considered when creating the parametric file:

1. There is no need to add post processing commands to the input file, since the program reads the file until it reaches 'solve and finish' command .
2. If the objective function variable is not available as a separate post processing item, such as heat flow into the workpiece, then a separate post-processing file is needed. This is explained in Appendix C.
3. It is a good idea to comment the design variables (on the same line) which are likely to be used as independent variable. Since the comment appears in the mouse documentation of the GBB software, it helps user in knowing what the variable means. If it is known that a variable is a constant or not going to be used for the experimental study, the same can be commented.
4. If the material library is used in the parametric file (using MATlLIB macro), all the materials and material properties defined in the library, though not used or assigned in the model, can be used as a material level.
   

The partial listing of the code is given as follows:

/TITLE,Thermal model of metal cutting
/PREP7
*afun,deg ! set all angles to degrees
! User input requests
pi = 3.1415 ! (Not a design variable, a constant)
d_cut=0.003937 ! (Indep Variable) Depth of cut(inches)
a=d_cut*25.4 !Depth of cut (mm)
speed=394 !cutting speed(sfm)
v=speed*300.4/60 ! convert sfm to mm/s
c_width=0.09842 !width_of_cut(in)
aw=c_width*25.4 ! convert inches to mm
shearang=30 !shearang
rake_ang=0 !rake_ang
flankang=1 !flank angle
wear=5 !tool_wear_as_%_of_coating
cut_forc=50 !cutting force(n)
t_force=30 !Thrust force(n)
hf=1000e-6 !conv_coeff_of_coolant
ha=100e-6 !con_coeff_of_air
to=25 !amb_temp

! Calculation of geometrical parameters

lf=1.75*a/sin(shearang) ! (not a design variable) chip - tool contact length
spec=0.00001 ! tolerance for spatial location
t_coat=0.5 ! thickness of tool coating in mm

! Calculation of heatfluxes

heat3=((cut_forc*sin(rake_ang)+t_force*cos(rake_ang))*(v/1000)*sin(shearang))
heat2=heat3/(cos(shearang-rake_ang)*lf*aw)
heat1=(cut_forc*(v/1000)-heat2*lf*aw)/(a*aw/sin(shearang))

! Declaration of element types and material properties

!element type declaration start
STAT
ET, 1,55 !element plane 55
KEYO, 1, 8, 1 !mass transportation option
R, 1 !real constant
RMOD, 1, 1,v ! velocity of element type 1 is 2 m/s

STAT
ET, 2,55
TYPE,2
REAL,2
KEYO, 2, 8, 1
R, 2
RMOD, 2, 1,v*cos(shearang)*sin(rake_ang)
RMOD, 2, 2,v*cos(shearang)*cos(rake_ang)
STAT
ET, 5,55
TYPE,5
REAL,5
R, 5
MP,DENS,1,7.8e-6 !material properties of workpiece
MP,C,1,500
MP,KXX,1,.0427
..................
..................
akw=0.0427
acw=500
rho=7.8e-6
alpa=akw/(acw*rho)
delta=(2*alpa/v)*0.9
l_b=25*delta
t=l_b/v
b=2*sqrt(alpa*t)

! Generation of the model

x1=0
y1=0
x2=10*delta
y2=0
.......
.........
........
.......
eshape,3,0
lccat,2,3
amesh,1
amesh,2,3
lccat,12,13
amesh,4,6
lccat,20,21
amesh,7,11
finish
/solu

sfl,4,conv,hf,,to
sfl,23,conv,hf,,to
sfl,26,conv,hf,,to
sfl,25,conv,hf,,to

allsel
nsel,s,loc,x,0-spec,0+spec
d,all,temp,to

allsel
nsel,s,loc,y,y29-spec,y29+spec
d,all,temp,to

allsel
sfl,12,conv,ha,,to
sfl,16,conv,ha,,to
........
........
sfl,7,hflu,heat1
sfl,20,hflu,heat2
sfl,21,hflu,heat2
allsel
solve
finish