Rolling operation
- Objectives: To analyze metal sheet rolling operation in Ansys workbench
- Geometrical Design:
For this analysis, we have a 3D model that consists of various parts such as Roller 1, Roller 2 and workpiece. This is how the whole assembly looks like;
- Material Properties:
In this analysis ingot made of copper will be used, the material for rollers will be structural steel. This is how some mechanical properties of these materials look like;
- Problem Statement:
Ingot made up of Copper Alloy will be used in this analysis. There will be two rollers that are rotated in such a way that ingot passes through them and due to pressure it will deform in shape of a sheet. Two rollers will rotate in the opposite direction with one another. When this analysis will complete will evaluate certain parameters such as Total Deformation, Equivalent Elastic Strain and Equivalent Stress.
- Mesh Criterion:
Element Type: Tet & Hex Elements (Mixed)
Element Size: 4 mm
Mesh Model:
- Boundary Condition:
Frictional Contacts: There is a contact that is present between ingot and roller. Both contacts kept as frictional. Co Efficient of Friction 0.2
Cylindrical Joints: There are two rollers present in this model; they will rotate opposite to one another. Two Cylindrical joints applied to both rollers.
- Loading & Analysis Setting:
Analysis Settings: Analysis is carried out in 14 steps, Large Deflection is kept on.
Displacement: Ingot applied with displacement in Y Direction
Joint Rotation:
- Post Process:
Case 1: Copper Alloy NL
Total Deformation
Directional Deformation (X-Axis)
Directional Deformation (Y-Axis)
Directional Deformation (Z-Axis)
Equivalent Elastic Strain
Equivalent Stress
Click here to see an animation of this project,
Post Process Results Summary;
Results & Conclusion:
1) Max Total Deformation is 90.25 mm.
2) Max Equivalent Elastic Strain is 0.022
3) Max Equivalent Stress is 2590.2
When we observe the deformation of a workpiece in Y Direction is nearly 90 mm. That tip portion nearly deformed around 90mm.