Copper Sheet Rolling
In metalworking, rolling is a metal forming process in which metal stock is passed through one or more pairs of rolls to reduce the thickness and to make the thickness uniform. The concept is similar to the rolling of dough.
In the following CASE copper sheet of 150 mm length is rolle with two rollers with a certain displacement of 90 mm respectively
Following is the CASE discussed
Fig. Geometry of Copper Rolling Simulation
Fig.Contact between Copper Sheet and rollers
The frictional contact co-efficient of 0.2 between the sheet and rollers is taken respectively.
Fig. Mesh Generation
Fig.Element quality
In this case the mesh generated is default Hex Mesh (Hex 20) with element length of 4mm
With corresponding:
NODES:7928
ELEMENTS:1278
BOUNDARY CONDITION:
In the above figure the boundary condition applied is:
Rotation of 210 degrees to both the rollers and corresponding displacment of sheet.
SOLUTION
i) Equivalent Stress:
Fig. Von Mises Stress for whole setup
ii) Plastic Strain of the workpiece
Fig. Plastic Strain of the workpiece
iii) Directional Deformation in Z direction
Fig. Directional Deformation in Z direction
iv) Prove that the workpiece has displaced by 90mm
In this case the displacement of 90mm is proven by getting directional displacement in Y direction in the applied boundary conditons.
Fig. Displacement of 90 mm
CONCLUSION:
Thus from above all cases and results follwing were the results observed respectively.