Analysis of Rolling Operation on a Copper Workpiece by using Ansys

Objective - To simulate the rolling operation on a workpiece made of copper. Increase the length of the workpiece by 60mm and decrease its size on both sides by 8mm. Run the simulation for 14 steps and you can give small but random values for the displacement. Ensure that the edge of the workpiece is displaced by 90mm.

Find out the

• Equivalent stress for the whole setup
• Equivalent Plastic strain for the workpiece
• Directional Deformation in the Z axis for the workpiece
• Prove that the workpiece has displaced by 90mm

Procedure -

• Create Static structural analysis and in engineering data select the material structural steel and copper alloy.
• Structural Steel.

• Copper Alloy.

• Import the geometry and check in SpaceClaim.

• Performed the following steps -
• Increase the length of the workpiece by 60mm.
• Decrease its size on both sides by 8mm.

• Then open Ansys mechanical and rename the geometry as Wheel1, Wheel2 and Workpiece then assign the structural steel material to Wheel1 and Wheel2 and Copper alloy material to Workpiece.

• Contacts - there are 2 contacts created in the whole setup with frictional type with friction coefficient of 0.2, formulation is set to augmented lagrange and normal stiffness type as factor and factor value is set to 0.1. The interface treatment is set to Add offset, Ramped Effects.

• Contact between Workpiece and Wheel1.

• Contact between Workpiece and Wheel2.

• Joint - both the rolling wheels have a Body to ground cylindrical joint.

• Mesh - Mesh the model using body size option for Workpiece with element size of 2mm.

• Analysis Settings - The simulation runs for 14 steps. So, the number of steps is set as 14, large deflection is set to on and stabilization set to constant, method to energy and energy dissipation ratio to 0.1.

• Displacement - the workpiece is provided with a displacement in negative y direction with small increment over the 14 steps.

• Joint - Rotation - the Wheel1 is provider with the rotation on 210degree.

• Joint - Rotation - the Wheel2 is provider with the rotation on -210degree.

• Run the simulation and results obtained.

Result - The analysis runs successfully and results obtained.

Equivalent Stress Max - 3181.7 Mpa

Equivalent Plastic Strain Max - 1.7003 mm/mm

Directional Deformation in the Z axis Max - 6.088 mm

Proof of the workpiece has displaced by 90mm

Animation - Equivalent Stress

Conclusion -

• The maximum Stress is experienced on the workpiece, at and around the edge that comes in contact with wheels. The minimum stress is observed on the outer edge of the wheels when they are not in contact with the workpiece. The maximum Equivalent Stress is 3181.7 Mpa
• The maximum plastic strain is also experienced at the edges of the workpiece in the direction in which they have deformed with a max value of 1.7003.
• Directional Deformation in the Z axis - The workpiece deforms by a maximum of 6.088 mm in the Z direction.
• Proof of the workpiece has displaced by 90mm - the Directional Deformation of the three curved surfaces on the lower tip of the workpiece shows the displacement of the workpiece by 90mm.

Google drive link - https://drive.google.com/file/d/11-zOnVe7c0vzezuYbogZQeKQNMea8vye/view?usp=sharing