Finite Element Analysis of rolling operation on a copper work piece using Ansys Workbench

Objective: Perform rolling operation on a workpiece made of copper and write a detailed report explaining the results obtained.

Question:

For this challenge, you will have to simulate the rolling operation on a workpiece made of copper. The model will be provided to you. Increase the length of the workpiece by 60mm and decrease its size on both sides by 8mm. Run the simulation for 14 steps and you can give small but random values( similar to the ones mentioned in the video) for the displacement. Ensure that the edge of the workpiece is displaced by 90mm.

Find out the

1. Equivalent stress for the whole setup
2. Equivalent Plastic strain for the workpiece
3. Directional Deformation in the Z axis for the workpiece
4. Prove that the workpiece has displaced by 90mm

Case Setup and Execution:

Model:

The length of the workpiece has been increased by 60mm and the width is decreased by 8mm on both the sides in the provided model.

Boundary Conditions:

Material: Structural Steel for Wheels and Copper for Work Piece.

Contacts: Frictional Contacts has been applied as shown below.

Joints: Cylindrical joints has been applied as shown below.

Mesh: Element Size - Default

Body Sizing: Work Piece Size of element- 3mm.

Analysis Settings:

Displacement: Displacement has been applied in the direction of y-axis on the z axis faces of work piece as shown below.

Joint Loads: Joint Loads has been applied as shown below.

Results:

1. Equivalent Stress for the whole setup:

2. Equivalent Plastic Strain for the work piece:

3. Directional Deformation in Z-axis for the work piece:

4. Prove that work piece has displaced by 90mm- Directional Deformation in Y-axis for the work piece:

Conclusion:

• Max.Equivalent Stress - 3258.7 Mpa.
• Max. Equivalent Plastic Strain for the work piece - 1.3182.
• Directional Deformation in the Z axis for the workpiece: Max. 5.0107mm, Min. -7.1021mm
• Proved that the workpiece has displaced by 90mm.