Week 4- Rolling operation

Analysis

Here we will see Structural Analysis for Rolling Copper Operation.

In which we will put a Copper Rod between two Rolls and extract the sheet form of Copper metal.

Here material will be Copper Alloy NL.

Procedure:

• Import model in Static Structural in Geometry section.
• Change in the geometry as follows:
• Increase length of Copper Workpiece by 60 mm.
• Decrease width of Copper Workpiece by 8 mm.
• We can see that final thickness of Copper rode has been 9 mm.
• Then go to Mechanical model section.
• • Type: Frictional
  • Friction Coefficient: 0.2
  • Formulation: Augmented Lagrange
  • Normal Stiffness : By factor
    • Normal Stiffness Factor: 0.1
  • Update Stiffness: Each Iteration
  • Interface Treatment: Add Offset, Ramped EffectsRename Roll Wheels and Copper rod as Wheel1, Wheel2 and Box as shown above in geometry
  • Connections:
    • Delete automatically created contacts and create new contacts as given below:

    Contact_1:

    Contact Body = Box

    Target Body = WHEEL1

    Contact_2:

    Contact Body = Box

    Target Body = WHEEL2

    Settings for both Contacts:

  Joints:

  Joint_1

  Connection Type: Body-Ground

  Type: Revolute

  Body: Wheel1

  Joint_2

  Connection Type: Body-Ground

  Type: Revolute

  Body: Wheel2

Boundary Conditions:

• After meshing as described above, create Boundary Conditions as given below:

Analysis Settings:

• No. of Steps: 14
• Auto Time Stepping: Program Controlled
• Solver Type: Program Controlled
• Large Deflection: ON
• Nonlinear Controls:
  • Stabilization: Constant
  • Method: Energy
  • Energy Dissipation Ratio: 0.1
• Other Boundary conditions for joints are as given below:
• Now we want to move the workpiece between two wheels up to 81 mm, so we have to give it a displacement.
• Select the surface of box and give displacement load and give values in tabular column
• Now select the wheels and give revolution joint load and give degree of rotation at each step in tabular graph
• Now run the simulation

Solution:

• After giving proper boundary conditions, create desired solutions for output results.
• Create Solutions for :
  • Equivalent Stress For Whole Setup
  • Equivalent Plastic Strain for the Box
  • Directional Deformation in Z-axis for the Box
  • Directional Deformation in Y-axis for the Box

Result:

Directional Deformation ( Y- Axis)

Directional Deformation (Z-Axis)

Equivalent Stress

Equivalent Plastic Strain

Proof for Displacement of Workpiece up to 90mm:

• Now we want to verify that workpiece has moved or displaced up to 90 mm in Y – Axis direction.
• As we know, we have given Displacement to Workpiece up to 90 mm.
• To verify it, we will see the Direction Deformation of the Workpiece and see that the Tip of the Workpiece has displaced up to 90mm or not.
• Here I gave a max displacement of 81mm so the displacement was 81mm

Conclusion:

This study of the rolling process drew every minute aspect. In terms of manufacturing engineering, every engineer should consider the rolling process as a core metal forming process. This process is mainly used when a cross-sectional area of a material required to be changed by an engineer.