Week 3- Rolling operation

ROLLING OPERATION

The model was imported and opened on space claim

According to the requirements of the question the length od the metal rod was increased to 80mm in length and the width was reduced by 8mm on both sides

The sheet was assigned the properties of copper alloy NL taken from non linear materials database and the two rollers were assigned structural steel

MESH

The default mesh yielded results any changes to the mesh resulted in errors

MESH QUALITY

The number of elements with element almost equal to 1 are more hence its a good quality of mesh

CONTACT

The contacts were defined between(as shown figuratively)

1)The top of the rod and the entire surface of the top roller

2)The bottom of the rod and the entire surface of the bottom roller

The contacts were defined as frictional with frictional value of 0.2,the problem formulation was said to be augmented lagrenge and the interface treatment was set to add offst and ramped loads

JOINTS

The joints are set to be to body to ground cylindrical joints and z axis was set the axis of rotation to both the roller

ANALYSIS SETTINGS

The total number of time steps was set to 14 and large deflection was switched on and in non linear controls stabilisation energy set to 0.1

LOADS

The displacement steps were defined gradually till 90mm as asked in the question

The rolleres were given angular rotation in z direction to the tune of 195 degrees

The top roller was made to rotate clockwise while the bottom roller was made to rotate anticlockwise

The solver was then hit solve and the following outputs were observed

OBSERVATIONS

DIRECTIONAL DEFORMATION IN Z DIRECTION FOR THE WORK PIECE

DISPLACEMENT OF WORKPIECE IS 90MM

STRESS IN SETUP

EQUIVALENT PLASTIC STRAIN

Results

The max equivalent stress in the setup is 3869Mpa and the average equivalent stress is 209Mpa

The proof for displacement of 90mm is provided in the video attached and the image attached above

The max deformation in z direction for the workpiece which is being flattened betwen two rollers is 4.8966mm

The workpiece is being flattened hence its elastic limit is exceeded and the max plastic strain in the workpiece is about1.3369