Week 4- Rolling operation

objective:For the given challenge setup the copper rolling operation and then simulate the rolling operation and then compare the results obtained during the simulation.

procedure:

1.first add the material copper in the engineering data of the geometry of non linear materials to the library and the structural steel.

2.Import the model into the space claim and increase the length of the workpiece to 60mm by using the pull option and then decrease the thickness size to 8mm on the both sides.

3.Import the model into the mechanical and rename the wheel 1 and 2 and the workpiece and then assign the material structural steel to the wheel1 and 2 and copper to the work piece.

Fig shows the import of the geometry model into the mechanical.

4.Define the contact from the wheel 1 to the work piece and wheel 2 to the work piece and flip the contacts and rename based on the defination.

5.Frictional contact of about the 0.1 and formulation be the augumented lagrange and interface treatment as the add offet stet ramped effects.

Fig shows the contact of the workpiece with the wheel1

Fig shows the contact of the work piece with the wheel2.

6.Define the cylindrical joints for both the wheel 1 and 2 to rotate about the z axis.

Fig shows the cylindrical joint for the wheel1 to rotate about the z axis.

Fig shows the cylindical joint for the wheel2 to rotate about the z axis.

7.Mesh the given model with the insert of the sizing of 4mm to the work piece and the remaining mesh as the default.

Fig shows the mesh of the given geometry with the sizing of 4mm.

8.In the analysis settings no of steps is taken as the 14 and the solver type as the direct and larger deflection to be on and insert the displacement of the work piece in negitive y direction as the min of -3 and max of -84.5mm.

Fig shows the displacement of the work piece given.

9.Define the rotation of the wheel 1 from +7 to the 210 degree for the 14 steps.

Fig shows the joint rotation of the wheel 2 in anticlock wise direction.

Fig shows the joint rotation of the wheel 1 in the clock wise direction.

10.In the solution add the equivalent stress, equivalent strain plastic, direct deformation of the work piece of 2 faces in the z direction and the direct deformation of the edge of the work piece in the y direction and the force reaction and the moment reaction .

Fig shows the min and max equivalent stress of min of 9.4858e-09mpa and max of the 2368mpa

Fig shows the equivalent plastic strain of min 0 mm/mm and max of 1.2809mm/mm.

Fig shows the directional deformation of the workpiece of min of -5.6124mm and max of 8.9334mm in z axis.

Fig shows the directional deformation of the edge of the work piece of the min of -84.515mm and max of -0.6mm.

Fig shows the pressure of the min and max in the workpiece min of 0mpa and max of 2946.7mpa.

Fig shows the force reaction of the work piece in y direction.

Fig shows the moment reaction of the work piece.

Results and comparision.

• The min and max equivalent stress of min of 9.4858e-09mpa and max of the 2368mpa .
• The equivalent plastic strain of min 0 mm/mm and max of 1.2809mm/mm.
• The directional deformation of the workpiece of min of -5.6124mm and max of 8.9334mm in z axis.
• The directional deformation of the workpiece of min of -5.6124mm and max of 8.9334mm in z axis.
• The directional deformation of the edge of the work piece of the min of -84.515mm and max of -0.6mm.

Conclusion:

In this challenge setup the copper rolling operation and run the simulation and the parameters find out for the evaluate of results is add the equivalent stress, equivalent strain plastic, direct deformation of the work piece of 2 faces in the z direction and the direct deformation of the edge of the work piece in the y direction and the force reaction and the moment reaction and evaluate the results.

NOTE:

The file size is to big so that the solution generated data will be cleared.