Week 4- Rolling operation

SIMULATION OF ROLLING OPERATION USING ANSYS WORKBENCH

Objective:

To simulate the rolling operation on a workpiece made of copper and increase the length of the workpiece by 60mm and decrease its size on both sides by 8mm. Run the simulation for 14. For the displacement of the workpiece by 90mm.

To simulate for the following results:

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

Setup for analysis:

Geometry:

Here , for simulation the length of work piece is asked to increase by 60mm and decrease width by 8mm on each side of work piece;

above are the results after modifying the geometry.

Material Properties:

Structural Steel is the material assigned for both the roller wheels, where as Copper Alloy NL is applied for work piece;

Connection Details:

Contact Details:

Here, the work piece is considered to be contact body and wheel1, wheel2 as target bodies , with frictional contact relation with coefficient of friction as 0.2 the formulation type of contact is Augmented Lagrange and normal stiffness value as 0.1 , stiffness is updated for each iteration and interface treatment as add offset, ramped effect.

Joint Details:

The type of joint selected for both the wheels is revolute type with connection type as body to ground.

Meshing:

Here , the body sizing for work piece is kept as 3mm with type as HEXA mesh, For wheels the mesh size is 5 mm with type as HEXA mesh.

The no of elements are 805 and no of nodes are 5379.

Analysis Settings:

The analysis is carried out in 14 steps with large diflections as ON with stabilization is constant and energy dissipation factor as 0.1,

Boundry conditions:

For work_piece;

Here , dsplacement of 90mm is provided in -y direction .

For wheels;

For wheels, rotation of 195 degree is provided in opposite directions for each wheel with an increment of 15 degree along z axis.

Results;

1.Equivalent stress:

Maximum Equivalent stress for the whole setup is 1815.8 MPa and minimum equivalent stress is 0.0031347MPa

2.Equivalent Plastic strain:

Maximum Equivalent plastic strain for the work piece is 1.1475 and minimum equivalent plastic strain is 0.

3. Directional Deformation in the Z axis for work piece:

Maximum deformation in Z axis for the work piece is 6.0316mm.

4.Directional Deformation in the Y axis for work piece:

Maximum deformation in Y axis for the work piece is 88.041 mm.

Conclusion:

1. The simulation of the rolling operation on a workpiece made of copper was made to run for 14
steps successfully.
2. The Max Equivalent stress for the whole setup is 1815.8MPa.
3. The Max Equivalent Plastic strain for the workpiece is 1.1475.
4. The Max Directional Deformation in the Z-axis for copper workpiece is 6.0316 mm.
5. The Directional Deformation in the Y-axis of workpiece is 88.041 mm which is aprox 90. Hence, it is
proved that the workpiece has displaced by 90mm.