Week 4- Rolling operation

Objective: simulation of sheet metal bending has done. This study compares the results at different cases.

In this study, simulation of the rolling operation on a workpiece made of copper has done . the edge of the workpiece is displaced by 90mm.

Result outcomes

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

This study is done in Ansys 2022

Introduction:

The rolling process is best defined as the shaping of metals into semi-finished or finished forms by passing between rollers rotating in opposite direction.

Procedure:

1.Geometry

• Input the model as Step format in geometry

2.Material assignment

• Open Engineering Materials and select the required material.
• Stainless steel is used as material in ANSYS for Roller and for workpiece metal plate with Copper Alloy NL material is used.

4..Meshing

• For Meshing the workpiece element size =4mm

3.Boundary condition

Connection

1.Contact creation

(a)

• Select the faces of gear teeth which will be in contact during simulation running
• Definition > type - Frictional
• Advanced > Formulation - Augmented Langrage
• Geometric Modification > Interface Treatment - Add offset Ramped effect

(b)

• Select the faces of gear teeth which will be in contact during simulation running
• Definition > type - Frictional
• Advanced > Formulation - Augmented Langrage
• Geometric Modification > Interface Treatment - Add offset Ramped effect

2.Joint creation

3.Analysis Setting

3. (a) Displacement of workpiece (Insert by right click on analysis setting)

3. (b) joint rotation of upper roller (Insert by right click on analysis setting)

3. (c) joint rotation of lower roller (Insert by right click on analysis setting)

Results (output):

Directional deformation (In negative Y direction)

Max deformation or displacement = 90mm

Stress

Max stress= 3482Mpa

Strain

Max plastic Strain =1.9027 mm/mm

Directional deformation (In z direction)

It is approximate 8mm on both side

Stress

Max stress= 6119Mpa

Whole setup animation

Conclusion:

Result shows that max equivalent stress in whole setup is 6119 Mpa and max equivalent stress in workpiece is 3482 Mpa and Max travelling distance of tip of workpiece is 90mm.