Challenge

Week 4- Rolling operation

DDilip Rambaran Jaiswal18 Feb 2023

Aim: To simulate the rolling operation on the workpiece made up of Copper and Equivalent stress,Equivalent plastic strain in the workpiece and directional deformationi in the workpiece.

Procedure:

select the statis structural model in ANSYS workbench .

Select the material in engineering tab

select material copper Alloy NL, in general non linear material,

The mechanical properties of Copper alloy NL material is given below

Density: 8300 kg/m³
Young's Modulus: 1.1e+05
Poisson's Ratio: 0.34
Bulk Modulus: 1.1458e+05 MPa
Shear Modulus: 41045 MPa
Specific Heat Constant Pressure: 3.85e+05 mJ/kg·°C

Import geometry and open in spaceclaim in ANSYS workbench

after that pull the workpiece length to upwork direction to 60 mm

Decrease the width of workpiece to 8 mm in z direction ,

repeat the same 8 mm decreasse the width of workpiece in opposite face

now exit from spaceclaim and update the geometry in model in static structural model, and open it using edit option

Now expand the geometry tab and rename as per convenient, in this case both roller we named as wheel1 and wheel 2 and workpiece

Also assign the workpiece material as Copper alloy NL, and both wheel and structural steel

now expand connection tab and flip the connection so that contact will be workpiece and target will be wheel 1 and wheel 2 , rename that base on connection.

select all connectiong faces like all wheel outer face as target and respective workpiece face

Now assign the conection as frictional and co efficient of friction as 0.2.
fromulation _ augmented lagrage
normal stiffness- factor
normal stiffness factor - 0.1
update stiffness- each ittration
interface treatment - add offset, ramped effect

NOw delpoy a cylindrical joint to both wheel as below
connection type - Body-ground
Type - cylindrical
rotate abount z axis as per given below , and select the inner face of wheel

for mesh: we will use defult generatef mesh on wheel , and for workpeice we will provide element size as 4 mm

Element quality :

as most of the element have good quality , in range od 0.6 to 1 we will proceed further with this mesh. the statics of the mesh given below

No of node:4137
No od element : 621

Analysis setup:

no of step ; 14
select all step and provide below setting
large deflection: On
Stabilization : constant
energy dissipation ratio:

now provide displacement to the workpiece , select 2 face of workpeice and provide load as displacement
Define by: component
y component - tubular data

in tubular data steps as per given below