Rolling operation

This challenge to simulate the rolling operation on a workpiece made of copper. The model is provided. Increase the length of the workpiece by 60mm and decrease its size on both sides by 8mm. Run the simulation for 14 steps and random values for the displacement. Ensuring that the edge of the workpiece is displaced by 90mm.

The model first imported to ansys and then material was set to structural steel for Wheels & and Copper Alloy NL for Bar.

we import the geometry and modify it in space claim. With help of space claim, we increase the length of workpiece by 60mm and reduce width from both side by 8mm.

Connections Settings :

we change the connections between the bodies as it is shown in the video. Providing frictional contact between the roller and the workpiece face which will come in contact during rolling. This will be done for both the rollers, setting the friction coefficient 0.2, normal stiffness factor 0.1 and changing contact behaviour to Adjust to offset (ramped).

Cylindrical joints are provided to both the rollers.

Mesh Setting :

Mesh is produced by default, only changing the mesh size of the workpiece to 4mm. It will result in a uniform mesh which can be seen below-

Analysis Settings :

we change the analysis settings as it was done like turning large deflection on and changing the number of steps to 14 etc.

Constraining the Workpiece movement along Y direction only by selecting to Side faces of it,providing the displacement to workpiece in tabular form which can be seen in below image

Joint Setting :

Now we set the boundary conditions, providing rotation to both rollers in opposite direction with respect to each other having values as shown in below image. These boundary condition can be seen below-

Applied Boundry Condition

Running the simulation and getting proper results

Simulation Result :

Equivalent stress for the whole setup

Equivalent Plastic strain for the workpiece

Directional Deformation in the Z axis for the workpiece

Proof that the workpiece has displaced by 90mm

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