Week 4- Rolling operation

Objective:- The objective of this challenge is to perform a static structural analysis and to simulate the rolling operation on a work piece made of copper for 14 steps and to ensure that the edge of the workpiece is displaced by 90mm. Finally to find out the equivalent stress for the whole setup, equivalent plastic strain for the workpiece, directional deformation in the Z axis for the workpiece and to prove that the workpiece had displaced by 90mm.

Procedure:-

1. Open the ANSYS workbench software. Under the analysis system select the static structure and wait for few seconds to pop up the window, which contains engineering data, geometry, model, setup, solution and results.

2. Under the geometry import the rolling copper model. Edit the model by importing it into spaceclaim, increase the length of the workpiece by 60mm and decrease its size on both sides by 8mm.

- Update the model by right click and edit the model for preprocessing.

- Under geometry rename its parts as wheel1, wheel2, workpiece and assign the material to the model Assign structural steel for both the wheels and assign copper alloy NL to the workpiece.

- Insert a joints for the two wheels by right clicking on connections and insert joint. Change connection type as body to ground, type as cylindrical and select the respective inner surface of wheels for scope.

- Then apply the joint load by right clicking on static structural -insert-joint load.

- Select the respected joint, change DOF as Rotation-Z, type as Rotational apply the magnitude in tabular data such as 0,7,15,30,45,60,75,90,105,120,135,150,165,180,195. Follow the same for another joint and use negative sign for the data to change the direction of rotation.

- Inserting displacement for the work piece by inserting displacement and assigning the value as -3,-6.5,-13-19.5,-26,-32.5,-39,-45.5,-52,-58.5,-65,-71.5,-79 and -90.

- In ANSYS automatic mesh will be performed with Default mesh size and change the mesh size as 6mm. Apply the mesh size of 3mm to the workpiece. Use method option to assign tetrahedrans for the model.

Meshing:-

The below figure shows the mesh size along with its number of nodes and elements.

- Analysis setting change no. of steps as 14, large deflection on , non linear stabilization as constant, energy disipation as 0.1.

- Now request for the outputs such as equivalent stress, equivalent elastic strain, directional deformation, stress and contact tool.

-Solve the solution and we can see the simulation run under solution information.

Results:-

Simulation results for the rolling operation on a workpiece made of copper.

Equivalent Stress:-

Equivalent stress;-

Directional Deformational (Y-axis)

Status of the copper rolling:-

Moment Reaction of the copper rolling:-

Tabulated Result:-

The above tabular data shows the equivalent stress, equivalent plastic strain, directional deformation(Z-axis), directional deformation(Y-axis), and pressure(MPa) of the copper material. Copper experiences a maximum equivalent stress of 3391.2 MPa, for the whole body, equivalent plastic strain for the workpiece is 1.9668, maximum directional deformation in the Z-axis for the workpiece is 5.5834mm, we has proved that the workpiece has displaced by 90mm by assigning the displacement value randomly, upto -90mm.

Conclusion:-

From the above result we can conclude that the equivalent stress of copper is 3391.2 MPa and this value is appropriate as it is followed by a grid dependency test. The workpiece has displaced by 90mm is proved by adding a random value to the displacement, upto 90mm and the tip of the workpiece is choosen as geometry and by the directional deformation the workpiece is displaced by 90mm.

Simulation:-

https://drive.google.com/file/d/1Hm2IbKqboYV72cylMeZdaCgoX_H153bx/view?usp=sharing