Simulation of Rolling operation using ANSYS Workbench

OBJECTIVE:

To simulate the rolling operation on a workpiece made of copper using ANSYS Workbench. The following objectives have to be satisfied.

1. To find equivalent stress for the whole setup

2. To find the equivalent plastic strain for the workpiece

3. To find the directional deformation in the z-axis for the workpiece

4. To prove that the workpiece has been displaced by 90mm.

PROCEDURE FOR CASE SETUP:

1. Open ANSYS>>Drag and drop static structural model in the project schematic window.

2. Go to the engineering data. Select copper alloy for the workpiece. The structural steel has to be used for rollers. Structural steel is the default material available in the library.

3. Go to the model tab for meshing and doing the case setup.

4. In the geometry rename the gear using a convenient name so that while assigning the boundary conditions it is easier to identify. In this case, the rollers are renamed as roller1 and roller2 respectively. The workpiece is named accordingly. The material copper alloy NL is assigned to the workpiece.

5. Go to contacts>>Define a frictional contact between the two gears with a frictional coefficient of 0.2. This is shown in the figure below.

6. The next important step is to define the joints for the rollers. The cylindrical joint is defined for the two rollers using the body to ground option in the joint option. This is shown below.

7. A mesh size of 2mm is chosen for the workpiece using the body sizing option. The mesh size of 1mm exceeds the nodes and element limitation on the academic version. Hence, 2mm is chosen for the simulation. The final meshed model is shown in the figure below.

8. The following analysis settings are defined for the simulation. The total number of steps defined for the simulation is 14.

9. The joint load definitions are explained in the figure below. For the top and bottom rollers, rotation is defined. 

10. The displacement of the two faces of the workpiece is defined as shown in the figure below.

11. From the solution option the results for equivalent stress and directional deformation along the z-axis for the faces of the workpiece are requested. Also, the directional deformation at the tip of the workpiece is requested. The equivalent plastic strain for the workpiece is requested. This is shown in the figure below.

12. From the analysis settings, hit on solve to start the simulation.

RESULTS AND DISCUSSION:

1. The equivalent stress for the whole setup is shown in the figure below.

2. The equivalent plastic strain for the workpiece is shown in the figure below.

3. The directional deformation along the z-axis is shown in the figure below.

4. The directional deformation along the y-axis is shown in the figure below.

ANIMATION FILES:

1. The animation file of equivalent stress is shown below.

2. The equivalent plastic strain of workpiece animation is shown below.

3. The directional deformation animation is shown below.

CONCLUSION:

The equivalent stress observed is 3224.5 MPa. The plastic strain observed in the workpiece is 1.9158. The directional deformation along z-axis is found to be 6.24 mm.

Therefore, from the results, it is proved that the displacement of the workpiece is 90mm (which is same as the directional deformation along the y-axis 89.538 mm)

Hence, all the objectives of the challenge are satisfied.

Drive Link: https://drive.google.com/file/d/1cMBfVtY5TdC7yfJ22E_10tIJeMsph6s0/view?usp=sharing