Rolling operation
OBJECTIVE
To perform the simulation of a rolling operation of copper wrokpiece using Ansys Workbench and study the output results such as equivalent stress , plastic strain and lateral deformation.
Importing the CAD model
The CAD model is imported and viewed using spaceclaim, the width of the copper workpiece is reduced by 8mm on both sides and length is increased by 90mm
Simulation setup
Material Assignment
The two rollers are defined as structural steel and the workpiece is defined as Copper alloy NL
Contact Definition
A frictional conctat is defined between the upper roller's outside surface and top surface of workpiece with a frictional coefficient of 0.2
Similar frictional contact is defined between lower roller's outside surface and bottom surface of workpiece.
Contact settings
Formulation - Augmented Lagrange
Normal stiffness factor - 0.1
Update stiffness - Each Iteration
Interface treatment - Add Offset, Ramped Effects
Joint creation
Body-Ground cylindrical joint is defined for both the rollers
Mesh Generation
The rollers are meshed with default settings. The roller body is selected and a sizing of 1mm is defined and meshed.
Analysis settings
Both the sides of workpiece are selected and given a displacement of 90 mm in negative Y-axis direction.
The two rollers are given 195 degree rotation in 14 steps.
The direction of rotation of rollers is opposite for each other
Results
Directional Deformation (z-axis)
Equivalent stress
Equivalent Plastic strain
Contact Status
Contact pressure
Ansys file link
https://drive.google.com/file/d/1YEKKtk_5i9alCV40dPRdFuw-udEMworb/view?usp=sharing