Week 4- Rolling operation

Title: Rolling Operation for Copper Workpiece.

Objective: To simulate and observe different parameters like Equivalent stress, Equivalent Plastic strain, Directional Deformation in the Z axis for the workpiece etc for Rolling of copper workpiece setup.

Modelling: Model is provided with two wheels and a workpiece. Modify workpiece length by 60mm and decrease thickness of workpiece by 8mm in both sides.

Material Assignment:

Wheels- structural steel

Workpiece- Copper Non-linear alloy

Contacts:

There are 2 contacts which are frictional and coeficient of friction of 0.2 and the formulation is augmented legrange with Normal stiffness factor of 0.1 and stifness updation for every iteration as mentioned in video is applied.

Joints: Cylindrical joints for wheels and displacment joint for workpiece in y direction.

Meshing: I have considered 4 mm element mesh body sizing for workpiece and default mesh size both the wheels. No of nodes for this geometry with this parameters are 4177.

Analysis settings: Set them as per video as 14 steps.

Loads:

Displacement is given to workpiece upto 90 mm in 14 steps.

Rotation is given to wheels.

Results of Rolling operation of copper workpiece:

1. Equivalent stress for the whole setup :

Maximum equivalent stress for this setup induced is 3060.6 Mpa and is induced between point of contact between wheel and workpiece.

2. Equivalent Plastic strain for the workpiece:

3.Directional Deformation in the Z axis for the workpiece:

Max directional deformation in z direction is 7.628 and min is 0.652 mm in one direction and the negative values indicates directional deformation in -ve z direction. max directional deformation in -ve z direction is 4.9278mm and min is 0.74mm.

4. Prove that the workpiece has displaced by 90 mm:

Tabulated results as below:

Material	Max.Equivalent stress(Mpa)	Max.Equivalent Plastic strain(mm/mm)	Max. Directional deformation in z direction(mm)
Copper NL alloy	3060.60	1.8311	7.628

Experiment:

I have refined mesh with nodes 25050 and tabulated results as follows but the file size is very large so i have used weak mesh and attached its file.

Material	Max.Equivalent stress(Mpa)	Max.Equivalent Plastic strain(mm/mm)	Max. Directional deformation in z direction(mm)
Copper NL alloy	3566.8	2.3248	7.8169