Rolling operation

Objective:

To simulate the rolling operation on a workpiece made of copper and to evaluate following results:

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

Geometry:

The provided geometry was imported in spaceclaim and its length was increased by 60mm and width was decreased by 8mm on both the sides.

Material:

Copper NL is used for workpiece & structural steel is used for rollers

Setting up the contact:

Frictional contact is set between workpiece and rollers

friction coefficient as 0.2

normal stiffness factor is 0.1

update stiffness :Each iteration

Interferance treatment : set offset,ramped effects

Joints:

Two joints created for two wheels with connection type of Body-ground

Mesh:

Body sizing set to program controlled

2.5 mm sizing assigned for workpiece

Analysis settings:

Simulation was performed in 14 steps assigning gradual displacement to the workpiece and rotation of wheel assigned approximately with diffrence of 15 degrees

Rotation assigned :

Displacement assigned:

Results:

Total Stress considering entire geometry

Stress considering workpiece:

Total strain:

2 Equivalent Plastic strain for the workpiece:

Max strain was found to be 0.0213 mm/mm

Min strain 0.00181mm/mm

3 Directional Deformation in the Z axis for the workpiece:

Max deformation 4.1353mm

4 Prove that the workpiece has displaced by 90mm :

We can see the workpiece is displaced by 90.5 mm as we can see in deformation plot

Report:

Conclusion:

Simulation was performed successfully

• Equivalent stress on plate of 2323.3 MPa
• Strain considering entire geometry 2.13e-2
• Directional deforamtion z axis 4.1353mm
• Plate was displaced by 90mm proven.