Week 4- Rolling operation

PROCEDURE

Open ANSYS Work bench, from the analysis systems drop the Static structural in Project schematic.

* Select required material from materials, which we need copper NL for workpiece.

* Import Geometry and open in design moduler to check the geometry. Increase the length of workpiece 60mm using extrude (add material) option and decrease the thickness of workpiece 8mm each side by using extrude (Cut material). Open inMechanical module and rename the parts for easy identification purpose.

* Select the contacts flip and rename them as per definition. and select required faces to allocate contact type.

*Insert two cylindrical joints from Body to Gound and allocate the inner cylindrical sufaces to create moment in simulation.

Type	Frictional
Friction Coefficient	0.2
Fomulation	Augmented Lagrange
Interface Treatment	Add offset, Ramped effects
Normal stiffness (factor)	0.1
Update stiffness	Each iteration

* In the Mesh change the Work piece mesh size as 3.0 MM steps and Large deflection should be ON, in Non-linear settings change Stabilization to Constant and Energy dispitation to 0.1

*Insert Displacement and enter 90 mm in tabular data with constant intervals as 6.0 mm each step.

* Insert two Joint loads and enter the tabular data shown in below picture upto 225 degress by looking at type of rotation.

* After setting all the above insert required outputs under solution and click onthe Solve.

RESULT

PRESSURE

FORCE REACTION

CASE 1: Equivalent stress for the whole setup

Successfully run simulate the rolling operation on a work piece made of copper. Increase the length of the work piece by 60mm and decrease its size on both sides by 8mm. Mesh size 4 mm. run the simulation for 14 number of steps for analysis setting.

From the bellow attached picture clearly seen that equivalent stress for whole setup.

Equivalent stress: 2312.4 MPa (max)

Equivalent stress: 0.012412 MPa (min)

CASE 2: Equivalent Plastic strain for the work piece

Equivalent Plastic strain: 1.2463 MM (max)

Equivalent Plastic strain: 0.0054715 MM (min)

Equivalent Plastic strain for the work piece along with negative Y-direction.

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

Directional Deformation: 5.278 mm (max)

Directional Deformation: -5.9825 mm (min)

CASE 4: Work piece has displaced by 90mm

Successfully run simulate the rolling operation on a work piece made of copper. Increase the length of the workpiece by 60mm and decrease its size on both sides by 8mm. mesh size 3.0 mm. Run the simulation for 16 number of steps for analysis setting and displacement extend upto 90 mm with negative Y direction and rotational joint also extend up to 225 degree for both Wheel1 and wheel2.

Directional deformation: -90 max mm.