Week 4- Rolling operation

Objective: To perform an analysis to simulate the rolling of copper material in ANSYS, and its results are validated.

1. Geometry:

Geometry is edited in space claim to increase the length of the copper workpiece to 60mm and thickness is reduced by 8mm on each side

2. Material data:

3. Case setup and settings:

a. Connections:

i. Contacts:

Frictional contacts (Coefficient of friction 0.2) are made from both wheels to the copper strip.

ii. Joints:

Cylindrical joints are made at the wheels with respect to the Z axis, (as shown in the fig. below).

b. Mesh

Face sizing is provided at the copper strip with an element size of 2 mm. Overall, the geometry is meshed with an element size of 4 mm.

C. Structural Input details:

i. Analysis setting:

ii. Displacement:

iii. Rotation joint:

Cylindrical joint is made with respect to the Z axis. The wheel is made to rotate about 195° for a sequential 14 steps with an interval of 15°. a negative angle is provided for the second wheel since it is in anti clock wise direction.

d. Solution:

i. Equivalent stress on the system:

ii. Equivalent Plastic strain for the workpiece:

iii. Directional Deformation in the Z axis for the workpiece:

iv. Directional Deformation in the y-axis for the workpiece:

Result:

(Max values are considered)	Equivalent stress on the system - MPa	Equivalent Plastic strain for the workpiece - mm	Directional Deformation in the Z axis for the workpiece - mm	Directional Deformation in the y-axis for the workpiece
Copper Alloy NL	3202.9	1.6892	6.5612	-89.482

The value of density of materials are, 8300 kgm^-3.

The value of yield strength of mentioned materials are, 280MPa.

5. Conclusion:

• The provided simulation can be further optimized using grid dependency test.
• The required challenges of the questions were solved and is stated in the result table.
• The Directional Deformation in the y-axis for the workpiece is validated and proved as the deformation obtained is approximately equal to 90 mm.