Week 4- Rolling operation

Rolling Operation Report

Aim: Simulate the rolling operation on a workpiece made of copper. Increase the length of the workpiece by 60mm and decrease its size on both sides by 8mm. Run the simulation for 14 steps and you can give small but random values for the displacement. Ensure that the edge of the workpiece is displaced by 90mm.

Find out the:

• Equivalent stress for the whole setup
• Equivalent Plastic strain for the workpiece
• Directional Deformation in the Z axis for the workpiece
• Prove that the workpiece has displaced by 90mm

Procedure:

• Select Static Structural, drag and drop into Project Schematic.
• Choose material of as Copper Alloy NL, under Engineering Data.
• Under geometry tab, import the given roller & workpiece geometry, double-click to open Space Claim to register the model.
• Then in Mechanical Module, assign Copper Alloy NL to the workpiece. The roller wheels can remain at structural steel.
• Assign a frictional connection between the rollers and workpiece with coefficient of friction = 0.2.
• Add 2 cylindrical joints to both wheels.
• The mesh size was set to default, but the workpiece was given 2mm mesh sizing.
• Under static structural tab, we set the analysis to 14 steps with auto timestep as programmed.
• A displacement on 90mm in 14 steps is given along Y axis for the workpiece.
• Joint loads in CW and CCW directions are given for the two wheels respectively. (up to 195deg rotational motion about Z-axis)
• Directional Deformation in Z-axis, Equivalent Plastic Strain and Equivalent Stress plots are requested from the solver as outputs.
• Directional Deformation in Y-axis to prove the workpiece travels for 90mm.
• Run the simulation by clicking on “solve”.

Conclusion:

Eq. Stress (MPa)	Eq. Plastic Strain	Direction Deformation (Z-axis) (mm)
2901.9	1.578	6.4861

We can see from the above table that the equivalent stress is high. This pushes the metal into plastic deformation and permanently deforms and flattens it. The image below proves that the workpiece has travelled for 90mm in distance.