Week 4- Rolling operation

Aim:-

To perform structural analysis to simulate rolling operation on a copper workpiece of length 90 mm

Structural analysis:-

Structural analysis is the process of calculating and determining the effects of loads and internal forces on a structure (or) an object.

Case setup:-

1. Assign the material for the roller as Structural steel and for the workpiece as Copper alloy( NL)

Procedure for Importing the model:-

1. Assign the material type to the model to be Imported using the tool Engineering data Edit ~ Engineering data sources.

Fig 1. Structural steel ( Material properties )

Fig 2.Copper alloy NL ( Material properties )

2. Import the model file using the tool Geometry ~ Import.

Procedure for Importing the model:-

1. Update the model to work on the model for structural analysis.

2. Under Model ~ geometry assign the name for a roller setup based on their application.

3. Under connection create contact 1 between the roller and workpiece and create another contact 2 between the roller 2 and the workpiece. Assign both the contact type as frictional and enter the frictional coefficient as 0.2.

Fig 3. Frictional contact between Wheel 1 and Workpiece.

Fig 4. Frictional contact between Wheel 2 and Workpiece.

4. Create a cylindrical joint for both the rollers in the z-direction.

5. Mesh the Workpiece with mesh sizing of 3 mm and the rollers with the default mesh size of 5 mm.

6. In the analysis settings tab under the static structural menu, set up the controls.

7. Under the static structural menu, create a displacement value to displace the workpiece in the y direction.

Fig 5. Displacement values are given for the Workpiece.

8. Under the static structural menu create a rotation joint for the rollers and provide the roller rotation angles for each step.

9. Insert the directional deformation and equivalent plastic strain, the workpiece, and von-mises stress solution for the Whole setup.

Results:-

Fig 6.Equivalent stress

Fig 7.Equivalent Plastic strain.

Fig 8. Directional deformation ( Z axis )

Fig 9. Directional deformation ( Y axis )

Conclusion:-

Overall, the structural analysis to simulate the rolling operation on a copper workpiece of length 90 mm is performed.