STRUCTURAL ANALYSIS OF COPPER ROLLING IN ANSYS

PROJECT OBJECTIVE: In this project, the aim is to simulate the rolling operation of a copper bar and to check the equivalent stress, equivalent plastic strain, directional deformation of the bar.

MODEL:

The model is being trimmed according to our needs in the SPACECLAIM. The length of the workpiece is increased by 60mm and the sides are decreased by 8mm from both sides.

MATERIAL:

The material used for the workpiece is copper alloy(non linear) and the material for rollers are structural steel.

The material properties are:

STAINLESS STEEL:

density:7850 kg/m3

youngs modulus:2e+11 Pa

poisson's ratio:0.3

bulk modulus:1.6e+11 Pa

compressive strength:2.5e+08 Pa

ultimate tensile strength:4.6e+08 Pa

tensile yield strength:2.5e+08 Pa

COPPER ALLOY:

density:8300

youngs modulus:1.1e+11 Pa

poisson's ratio:0.34

bulk modulus:1.1458e+11 Pa

compressive strength:2.5e+08 Pa

tensile yield strength:2.8e+08 Pa

shear modulus:

tangent modulus:1.15e+09 Pa

MESHING:

The meshing is done by 4mm mesh, which is assumed to give accurate results.

CONTACT DETAILS:

FRICTIONAL CONTACTS are used with a friction coefficient of 0.2

FORMULATION: augmented lagrange

NORMAL STIFFNESS FACTOR: 0.1

INTERFACE TREATMENT: add offset, ramped effects

JOINTS:

The rollers are given BODY TO GROUND -CYLINDRICAL JOINTS with a total rotation of 195 degree and the workpiece is given a displacement of 90mm.

ANALYSIS SETTINGS:

Number of steps: 14

large deflection: on

stabilization:constant

energy dissipation ratio:0.1