Week 4- Rolling operation

Aim : To perform static structural analysis on rolling operation.

Objectives :

1. Equivalent stress for the whole setup.
2. Equivalent Plastic strain for the workpiece.
3. Directional Deformation in the Z axis for the workpiece.
4. Prove that the workpiece has displaced by 90mm.

Procedure :

Engineering data and material :

• Open engineering data.
• Go to general non linear material from engineering data sources.
• Add Copper Alloy NL to library.

Geometry :

• Import geometry.
• Increase the length of the workpiece by 60mm using Pull tool.
• Decrease its size on both sides by 8mm using Pull tool.

Model Setup :

• Open geometry and rename the components as Wheel 1 and 2, Workpiece.
• Assign Copper Alloy NL as material to Workpiece.

Contacts :

• Select both contacts flip contacts and rename based on defination.
• Create contact between Wheel 1 and Workpiece.

• Create contact between Wheel 2 and Workpiece.

• Select both contacts and set following parameters

Joints :

• Create cylindrical joint for Wheel 1 and Wheel 2.
• Change co-ordinate system z-axis position opposite to global co-ordinate system.

Meshing :

• Insert sizing for Workpiece and element size as 3 mm.
• Give general mesh size as 3 mm.
• Generate mesh.

Analysis Setting :

Displacement :

• Insert displacement for workpiece. Select front faces to constrain the motion.

Joint load :

• Create rotational joint for Wheel 1 and 2.
• Give negative to values to change direction of rotation.

Solution :

Create output results for :

• Directional deformation along Z-axis.
• Directional deformation along Y-axis.
• Equivalent plastic strain for workpiece.
• Equivalent stress for whole setup.

Results :

Equivalent stress for the whole setup :

Equivalent Plastic strain for the workpiece :

Directional Deformation in the Z axis for the workpiece :

Displacement of workpiece :

Conclusion :

• Equivalent stress for the whole setup
  • Maximum = 5006.5 MPa
  • Minimum = 0.001816 MPa
• Equivalent Plastic strain for the workpiece
  • Maximum = 1.8619
  • Minimum = 0.01410
• Directional Deformation in the Z axis for the workpiece
  • Maximum = 10.64 mm
  • Minimum = -0.6281 mm
• Displacement of workpiece = 90 mm.