Simulation of rolling operation of a Copper work-piece using Ansys

Objective:

To simulate rolling operation on a workpiece made up of copper using Ansys.

Procedure:

Static structural analysis system is opened in the project schematic window of Ansys workbench and renamed as Rolling copper.

In Engineering data,copper material is added required for the analysis.

Geometry:

The given model is imported in the geometry option and modified in design modeller as follows.

The length of the workpiece is incresed by 60mm and its size decreased on both sides by 8mm.

Original geometry

Modified geometry

Meshing:

In Mechanical, the workpiece is meshed with 2mm and the wheels are given a edge sizing with number of divisions as 15.

The mesh is generated.

Contacts:

Frictional contacts are created between the wheels and the workpiece with a frictional coefficient of 0.2 and the formulation is done by augmented Lagrange method.

The normal stiffness is defined by a factor of 0.1 and the stiffness is updated for each iteration.

Joints:

Cylindrical type joint is preferred for both the wheels with a connection type of Body to Ground.

Boundary conditions:

The simulation is made run for 14 steps with following conditions.

The faces of the workpiece are given a displacement condition as given in the tabular column.

Rotational joint loads are defined for both the wheels in opposite directions as required for the analysis.

Results:

In solution,the following terms are requested to solve.

1.Equivalent stress for the whole setup

2.Equivalent plastic strain for the workpiece

3.Directional deformation in lateral direction of the workpiece

4.Displacement for the workpiece

Conclusion:

From the results,it is found that

1.Equivalent stress for the whole setup =Minimum of 1.0398 MPa and maximum of 6350.1 MPa

2.Equivalent plastic strain for the workpiece =Minimum of 0.020056 and maximum of 1.5521

3.Directional deformation in lateral direction of the workpiece =Minimum of 2.9959 mm and maximum of 14.072 mm.

4.Displacement for the workpiece =90mm

Hence it is proved that the diplacement of wokpiece is upto 90mm.