Week 4- Rolling operation

Aim :

       To perform rolling operation and analyse the model for required solution by using ANSYS software.

Objective :

       To perform rolling operation for the given model with geometry changes and to analyse the model for.

Equivalent stress of the whole model,

Equivalent plastic strain of the work piece,

Directional deformation of work piece in Z axis,

Directional deformation of work piece in Y axis to check the displaced value 90mm.

Given model :

       Rolling is a metal forming process in which metal stock is passed through one or more pairs of rolls to reduce the thickness, to make the thickness uniform, and to impart a desired mechanical property.

Procedure :

We start from workbench and choose static structural analysis.

In static structural we add material property which is required for the analysis.

We import the given model to the geometry tab.

Here we do the required changes which is asked to perform in the geometry by using spaceclaim.

These operations are performed in work bench and for model tab we move to mechanical setup screen.

In mechanical window we add data which is required to solve the process.

We define the material for workpiece and the rest components will be assigned as default material.

We define the friction between the different components. Here between upper face of workpiece and upper roller, bottom face of the workpiece and bottom roller.

The behaviour is defined as auto asymmetric and we us ethe formula as Augmented Lagrange.

We define the normal stiffness factor as 0.1 and interface as add offset, ramped effect.

We define the joints as body to ground cylindrical.

For meshing the work price is meshed for 1.5mm to attain accurate values and the rollers are meshed for default values.

In analysis part we do the analysis for 14 steps, change large deflection ON, we change the nonlinear controls stabilization as constant with energy dissipation ratio of 0.1.

We define the tabular value for displacement for machining the work piece.

In this model it is asked to show the displacement of workpiece at 90mm. so the maximum value of displacement is assigned as 90mm.

We define the values for rotation of rollers for rolling process by joint operation.

In solution part we define the required solution for the given model and the results are shown below.

Equivalent stress of the whole model :

Equivalent plastic strain of the work piece :

Directional deformation of work piece in Z axis :

Directional deformation of work piece in Y axis to check the displaced value 90mm :

Conclusion :

       In this model it is asked to modify the geometry and do the analysis for what is asked. We did the geometry modification and analysis for the given model. The solution values with images are given below.

Workpiece material/solution	Equivalent plastic strain of the workpiece	Directional deformation of work piece in Z axis	Displacement of workpiece in Y axis
Copper alloy NL	1.4744mm (max)	7.5038mm (max)	-90mm

Result :

       The given model is analysed and got the required solution successfully by using ANSYS software.