Challenge

Rolling Operation

MMaheswaran Mathivanan17 Jan 2021

Aim:

To simulate the rolling operation on a workpiece made of copper.

Objective:

Increase the length of the workpiece by 60 mm and decrease its size on both sides by 8 mm. Run the simulation for 14 steps and you can give small but random values for the displacement. Ensure that the edge of the workpiece is displaced by 90 mm.

Find out the

Equivalent stress for the whole setup.
Equivalent Plastic strain for the workpiece.
Directional Deformation in the Z axis for the workpiece.
Prove that the workpiece has displaced by 90mm.

Procedure:

We will first import the model into ANSYS-WORKBENCH and then open the Geometry module and then we will modify the model in Space Claim module to the given requirements as in the objective.

After we edit the geometry according to the given requirements and we will be providing the boundary conditions for the workpiece and the rollers.

At first we will be providing contacts as frictional for the workpiece to the roller wheel 1 and wheel 2 separately as shown in the two images below.

Then we will be providing joints as ground to wheel in cylindrical so that the roller wheels will be fixed and it will allow the workpiece to penetrate in between them with the required displacement as shown in the two images below.

Now, we will be providing boundary conditions for the mode by starting with the displacement in the negative direction in 14 steps to cover a displacement of 90 mm as shown in the image below.

We will then be providing joint rotation to both the roller wheels in degrees of rotation in which one roller wheel will have positive values and the other one will have the same values but negative same values as shown in the images below.

Simulation:

Case 1:

Equivalent Stress:

	Time [s]	Minimum [MPa]	Maximum [MPa]	Average [MPa]
1	0.2	2.38E-05	356.97	11.662
2	0.4	7.09E-09	443.56	18.797
3	0.7	1.40E-07	608.17	26.956
4	1	1.77E-07	781.09	32.844
5	1.2	1.30E-08	814.58	36.071
6	1.4	2.64E-08	820.09	39.673
7	1.7	4.44E-08	891.54	44.905
8	2	1.04E-07	921.99	48.636
9	2.194	5.33E-07	1195.5	56.483
10	2.2619	4.68E-07	1264.9	59.78
11	2.3298	6.86E-07	1312.9	62.427
12	2.4317	7.08E-07	1388.5	65.408
13	2.5611	5.96E-07	1401.7	69.822
14	2.6905	3.17E-07	1600.1	73.185
15	2.8364	9.12E-07	1596.9	79.02
16	2.9182	1.57E-06	1550.8	81.719
17	3	1.92E-06	1536.5	84.34
18	3.1263	1.30E-06	1624.8	89.106
19	3.2527	8.66E-07	1756.4	93.604
20	3.3756	1.25E-05	1788	99.458
21	3.4985	4.78E-06	1727.5	103.12
22	3.6402	1.38E-05	1753.7	103.38
23	3.782	2.66E-06	1698.5	106.53
24	3.9122	3.22E-06	1620.5	110
25	4	9.36E-06	1657.9	113.33
26	4.1219	1.62E-05	1655.8	115.93
27	4.2438	1.42E-05	1678.8	117.47
28	4.383	8.98E-06	1701.4	120.34
29	4.5099	4.45E-05	1800.1	124
30	4.6367	4.64E-05	1942.8	127.37
31	4.758	5.75E-05	1960.1	130.18
32	4.8793	3.62E-05	1913.5	132.16
33	5	2.74E-05	1815.9	134.37
34	5.1295	9.21E-05	1765.7	138.8
35	5.259	1.84E-04	1903.7	139.94
36	5.397	1.65E-04	1979	142.21
37	5.537	1.12E-04	1976.4	144.19
38	5.6654	2.37E-04	1841.4	148.36
39	5.7938	3.46E-04	1782.5	150.31
40	5.9314	6.30E-04	1850.2	151.68
41	6	4.96E-04	1909.6	153.26
42	6.1308	1.48E-04	2037.3	155.43
43	6.2617	4.79E-04	2152.5	159.25
44	6.3831	2.55E-04	2226.3	160.18
45	6.5045	7.47E-04	2197.1	161.3
46	6.6415	1.31E-03	1998.1	162.99
47	6.7681	4.74E-04	1805	166.35
48	6.8946	8.08E-04	1983.4	168.28
49	7	7.03E-04	2015.3	167.79
50	7.1281	6.67E-04	2001.1	169.15
51	7.2562	6.53E-04	1949.7	170.64
52	7.3846	6.68E-04	1879.2	173.48
53	7.513	6.95E-04	1961.8	172.98
54	7.6332	4.80E-04	1972.2	173.02
55	7.7535	1.86E-04	1877	174.3
56	7.8799	5.65E-04	1880.9	175.88
57	8	4.58E-04	1867.6	177.87
58	8.1221	1.21E-03	2005.4	177.31
59	8.2442	2.55E-04	2006.1	177.85
60	8.382	6.76E-04	1894.2	179.46
61	8.5086	5.00E-04	1906.5	182.23
62	8.6352	3.20E-04	1865.3	183.24
63	8.7552	1.64E-04	1945.5	183.46
64	8.8751	3.11E-04	1949.9	185.74
65	9	3.23E-04	1902.9	187.24
66	9.1304	7.21E-04	1840.8	190.29
67	9.2608	1.64E-04	2008.1	191.53
68	9.397	8.38E-04	1964.4	193.7
69	9.5361	7.28E-04	1851.2	195.22
70	9.6644	2.87E-04	1882.8	199.26
71	9.7927	5.46E-04	1878.4	201.65
72	9.9137	1.22E-04	1913.2	202.79
73	10	1.77E-04	1874.6	204.64
74	10.132	6.91E-04	1730.1	207.25
75	10.263	3.18E-04	1710.5	211.32
76	10.401	1.91E-04	1897.3	213.05
77	10.539	3.52E-04	1978.9	215.91
78	10.679	2.09E-04	1826.5	219.6
79	10.807	2.24E-04	1887.5	224.78
80	10.936	3.82E-04	2160.4	226.49
81	11	1.87E-04	2245.2	227.25
82	11.129	3.64E-04	2283	229.52
83	11.257	3.23E-04	2032.2	231.53
84	11.386	2.26E-04	1894.5	235.45
85	11.514	2.39E-04	2269.2	236.9
86	11.635	1.95E-04	2489.1	238.2
87	11.756	3.26E-04	2481.3	239.37
88	11.883	3.87E-04	2208.8	241.35
89	12	3.36E-04	1864.9	241.96
90	12.07	1.18E-03	1920.3	241.13
91	12.14	2.64E-04	1929.4	240.36
92	12.245	2.41E-04	1958.6	240.49
93	12.384	4.37E-04	1921.1	241.04
94	12.51	5.84E-04	1771.4	243.41
95	12.637	4.93E-04	1878	242.59
96	12.761	2.91E-04	1938.6	241.74
97	12.886	5.07E-04	1929.8	241.91
98	13	1.27E-03	1844.4	243.63
99	13.131	5.02E-04	1707.6	245.31
100	13.261	7.46E-04	1835.7	243.13
101	13.413	4.56E-04	1959.2	243.43
102	13.564	8.02E-04	1975.1	244.85
103	13.722	4.71E-03	2044.6	245.96
104	13.889	2.25E-03	2256.4	244.64
105	14	2.93E-03	2293.9	245

Simulation Video - https://drive.google.com/file/d/1x-OiPqqr3BZATf_Xry8OkLXLTlUBVqot/view?usp=sharing

Equivalent Plastic Strain:

	Time [s]	Minimum [mm/mm]	Maximum [mm/mm]	Average [mm/mm]
1	0.2	0	2.15E-02	5.66E-04
2	0.4	0	6.35E-02	2.41E-03
3	0.7	0	0.15627	7.53E-03
4	1	0	0.26248	1.48E-02
5	1.2	0	0.31151	1.93E-02
6	1.4	0	0.35698	2.38E-02
7	1.7	0	0.43217	3.08E-02
8	2	0	0.4991	3.78E-02
9	2.194	0	0.56623	4.86E-02
10	2.2619	0	0.58558	5.27E-02
11	2.3298	0	0.59915	5.66E-02
12	2.4317	0	0.61866	6.29E-02
13	2.5611	0	0.68763	7.06E-02
14	2.6905	0	0.74314	7.80E-02
15	2.8364	0	0.79265	8.67E-02
16	2.9182	0	0.81557	9.18E-02
17	3	0	0.83643	9.70E-02
18	3.1263	0	0.87234	0.10443
19	3.2527	0	0.91314	0.11225
20	3.3756	0	0.94275	0.11992
21	3.4985	0	0.96093	0.12764
22	3.6402	0	1.0007	0.13566
23	3.782	0	1.041	0.14364
24	3.9122	0	1.0672	0.151
25	4	0	1.0814	0.15637
26	4.1219	0	1.095	0.16361
27	4.2438	0	1.1005	0.17052
28	4.383	0	1.1031	0.17844
29	4.5099	0	1.1047	0.18593
30	4.6367	0	1.1055	0.19375
31	4.758	0	1.1057	0.20082
32	4.8793	0	1.1091	0.20762
33	5	0	1.1119	0.21477
34	5.1295	0	1.1139	0.2225
35	5.259	0	1.1142	0.23029
36	5.397	0	1.1143	0.23812
37	5.537	0	1.1143	0.24621
38	5.6654	0	1.1143	0.25394
39	5.7938	0	1.1143	0.26172
40	5.9314	0	1.1143	0.26958
41	6	0	1.1143	0.27348
42	6.1308	0	1.1143	0.28107
43	6.2617	0	1.1143	0.28904
44	6.3831	0	1.1143	0.29643
45	6.5045	0	1.1143	0.30339
46	6.6415	0	1.1143	0.31114
47	6.7681	0	1.1143	0.31867
48	6.8946	0	1.1143	0.32644
49	7	0	1.1143	0.33269
50	7.1281	0	1.1143	0.33977
51	7.2562	0	1.1143	0.34734
52	7.3846	0	1.1143	0.35512
53	7.513	0	1.1143	0.36293
54	7.6332	0	1.1143	0.36988
55	7.7535	0	1.1143	0.37669
56	7.8799	0	1.1143	0.38414
57	8	0	1.1143	0.39147
58	8.1221	0	1.1143	0.39876
59	8.2442	0	1.1143	0.40578
60	8.382	0	1.1143	0.41368
61	8.5086	0	1.1143	0.42131
62	8.6352	0	1.1143	0.42909
63	8.7552	0	1.1143	0.43613
64	8.8751	0	1.1143	0.4429
65	9	0	1.1143	0.45014
66	9.1304	0	1.1143	0.45794
67	9.2608	0	1.1143	0.46601
68	9.397	0	1.1143	0.47379
69	9.5361	0	1.1143	0.48169
70	9.6644	0	1.1143	0.48939
71	9.7927	0	1.1143	0.49732
72	9.9137	0	1.1143	0.50431
73	10	0	1.1143	0.50917
74	10.132	0	1.1143	0.51671
75	10.263	0	1.1143	0.52474
76	10.401	0	1.1143	0.53317
77	10.539	0	1.1143	0.54102
78	10.679	0	1.1143	0.54895
79	10.807	0	1.1143	0.55669
80	10.936	0	1.1143	0.56458
81	11	0	1.1143	0.56842
82	11.129	0	1.1143	0.57554
83	11.257	0	1.1143	0.58303
84	11.386	0	1.1143	0.59084
85	11.514	0	1.1143	0.59889
86	11.635	0	1.1143	0.60598
87	11.756	0	1.1143	0.61289
88	11.883	0	1.1143	0.62044
89	12	0	1.1143	0.62769
90	12.07	0	1.1143	0.632
91	12.14	0	1.1143	0.63642
92	12.245	0	1.1143	0.64239
93	12.384	0	1.1143	0.65028
94	12.51	0	1.1143	0.6577
95	12.637	0	1.1143	0.66506
96	12.761	0	1.1143	0.67209
97	12.886	0	1.1143	0.67859
98	13	0	1.1143	0.68468
99	13.131	0	1.1143	0.69137
100	13.261	0	1.1143	0.69791
101	13.413	0	1.1143	0.70582
102	13.564	0	1.1143	0.71415
103	13.722	0	1.1143	0.72211
104	13.889	0	1.1143	0.72937
105	14	0	1.1143	0.73389

Simulation Video - https://drive.google.com/file/d/1mwyyAjccO_Ex_ofkUp9RfI0DDJ8zvCjb/view?usp=sharing

Directional Deformation (Z axis):

	Time [s]	Minimum [mm]	Maximum [mm]	Average [mm]
1	0.2	-4.12E-03	6.89E-02	3.30E-02
2	0.4	-9.95E-02	0.1653	3.31E-02
3	0.7	-0.33584	0.4029	3.35E-02
4	1	-0.64277	0.71065	3.38E-02
5	1.2	-0.8098	0.86709	2.85E-02
6	1.4	-0.9459	1.0028	2.83E-02
7	1.7	-1.1504	1.2067	2.80E-02
8	2	-1.3819	1.4373	2.77E-02
9	2.194	-16.704	-13.208	-14.956
10	2.2619	-16.821	-13.092	-14.956
11	2.3298	-16.92	-12.993	-14.957
12	2.4317	-17.112	-12.803	-14.958
13	2.5611	-17.388	-12.529	-14.958
14	2.6905	-17.634	-12.284	-14.959
15	2.8364	-17.93	-11.99	-14.96
16	2.9182	-18.113	-11.807	-14.96
17	3	-18.289	-11.632	-14.961
18	3.1263	-18.621	-11.512	-15.067
19	3.2527	-18.877	-11.271	-15.074
20	3.3756	-19.133	-11.028	-15.081
21	3.4985	-19.329	-10.844	-15.087
22	3.6402	-19.539	-10.649	-15.094
23	3.782	-19.745	-10.454	-15.1
24	3.9122	-19.902	-10.306	-15.105
25	4	-19.996	-10.219	-15.108
26	4.1219	-20.153	-10.197	-15.176
27	4.2438	-20.204	-10.15	-15.179
28	4.383	-20.233	-10.126	-15.182
29	4.5099	-20.307	-10.061	-15.185
30	4.6367	-20.439	-9.9345	-15.188
31	4.758	-20.526	-9.8523	-15.191
32	4.8793	-20.583	-9.7996	-15.193
33	5	-20.623	-9.7638	-15.196
34	5.1295	-20.646	-9.7175	-15.184
35	5.259	-20.659	-9.7026	-15.183
36	5.397	-20.665	-9.6968	-15.182
37	5.537	-20.715	-9.6466	-15.181
38	5.6654	-20.754	-9.6054	-15.18
39	5.7938	-20.773	-9.5838	-15.179
40	5.9314	-20.776	-9.5791	-15.178
41	6	-20.777	-9.5781	-15.178
42	6.1308	-20.787	-9.5993	-15.194
43	6.2617	-20.788	-9.6025	-15.195
44	6.3831	-20.806	-9.585	-15.196
45	6.5045	-20.811	-9.5814	-15.196
46	6.6415	-20.809	-9.585	-15.197
47	6.7681	-20.805	-9.5896	-15.197
48	6.8946	-20.801	-9.594	-15.198
49	7	-20.803	-9.5972	-15.198
50	7.1281	-20.776	-9.5643	-15.168
51	7.2562	-20.769	-9.5691	-15.167
52	7.3846	-20.765	-9.5713	-15.166
53	7.513	-20.771	-9.5679	-15.165
54	7.6332	-20.774	-9.5625	-15.164
55	7.7535	-20.773	-9.5625	-15.163
56	7.8799	-20.767	-9.567	-15.162
57	8	-20.763	-9.5688	-15.162
58	8.1221	-20.766	-9.5711	-15.164
59	8.2442	-20.769	-9.5714	-15.165
60	8.382	-20.765	-9.5716	-15.165
61	8.5086	-20.761	-9.5718	-15.165
62	8.6352	-20.77	-9.5719	-15.165
63	8.7552	-20.776	-9.5666	-15.165
64	8.8751	-20.777	-9.566	-15.166
65	9	-20.771	-9.5718	-15.166
66	9.1304	-20.651	-9.4552	-15.049
67	9.2608	-20.647	-9.4526	-15.045
68	9.397	-20.647	-9.4497	-15.042
69	9.5361	-20.639	-9.4469	-15.039
70	9.6644	-20.633	-9.4444	-15.036
71	9.7927	-20.63	-9.4421	-15.033
72	9.9137	-20.628	-9.4402	-15.031
73	10	-20.627	-9.4391	-15.03
74	10.132	-20.591	-9.4033	-14.995
75	10.263	-20.591	-9.4034	-14.995
76	10.401	-20.597	-9.4032	-14.994
77	10.539	-20.599	-9.4003	-14.994
78	10.679	-20.593	-9.4024	-14.993
79	10.807	-20.59	-9.402	-14.993
80	10.936	-20.589	-9.4016	-14.992
81	11	-20.589	-9.4014	-14.992
82	11.129	-20.586	-9.3979	-14.989
83	11.257	-20.586	-9.3981	-14.989
84	11.386	-20.586	-9.3982	-14.989
85	11.514	-20.593	-9.3952	-14.989
86	11.635	-20.598	-9.3909	-14.989
87	11.756	-20.596	-9.392	-14.989
88	11.883	-20.591	-9.397	-14.989
89	12	-20.588	-9.3982	-14.989
90	12.07	-20.588	-9.3998	-14.991
91	12.14	-20.588	-9.3999	-14.991
92	12.245	-20.59	-9.3999	-14.991
93	12.384	-20.588	-9.4	-14.991
94	12.51	-20.588	-9.4	-14.991
95	12.637	-20.588	-9.4001	-14.991
96	12.761	-20.588	-9.4002	-14.991
97	12.886	-20.588	-9.4002	-14.991
98	13	-20.588	-9.4002	-14.991
99	13.131	-20.502	-9.3142	-14.905
100	13.261	-20.501	-9.3135	-14.904
101	13.413	-20.5	-9.3123	-14.903
102	13.564	-20.499	-9.3111	-14.901
103	13.722	-20.498	-9.3101	-14.9
104	13.889	-20.497	-9.3092	-14.899
105	14	-20.496	-9.3086	-14.899

Simulation Video - https://drive.google.com/file/d/1dhvbENuAbf2aa9kubMSjvllK4z5PpNJm/view?usp=sharing

Workpiece displaced by 90 mm:

	Time [s]	Minimum [mm]	Maximum [mm]	Average [mm]
1	0.2	-0.63112	-0.62865	-0.62988
2	0.4	-1.3052	-1.2973	-1.3015
3	0.7	-2.3349	-2.3169	-2.3266
4	1	-3.3793	-3.3509	-3.3667
5	1.2	-4.1192	-4.0868	-4.105
6	1.4	-4.8396	-4.8058	-4.8249
7	1.7	-5.9332	-5.8985	-5.9179
8	2	-7.0274	-6.9912	-7.0114
9	2.194	-8.405	-8.3678	-8.3888
10	2.2619	-8.8773	-8.8398	-8.861
11	2.3298	-9.3465	-9.3091	-9.3303
12	2.4317	-10.069	-10.031	-10.052
13	2.5611	-10.989	-10.951	-10.973
14	2.6905	-11.907	-11.87	-11.891
15	2.8364	-12.935	-12.897	-12.918
16	2.9182	-13.517	-13.479	-13.5
17	3	-14.106	-14.067	-14.089
18	3.1263	-15.021	-14.983	-15.004
19	3.2527	-15.931	-15.893	-15.914
20	3.3756	-16.828	-16.79	-16.811
21	3.4985	-17.735	-17.696	-17.717
22	3.6402	-18.792	-18.753	-18.774
23	3.782	-19.838	-19.799	-19.82
24	3.9122	-20.781	-20.742	-20.762
25	4	-21.41	-21.371	-21.391
26	4.1219	-22.286	-22.248	-22.268
27	4.2438	-23.142	-23.103	-23.123
28	4.383	-24.119	-24.081	-24.101
29	4.5099	-25.009	-24.971	-24.991
30	4.6367	-25.899	-25.86	-25.88
31	4.758	-26.749	-26.71	-26.73
32	4.8793	-27.598	-27.559	-27.579
33	5	-28.443	-28.404	-28.424
34	5.1295	-29.352	-29.314	-29.334
35	5.259	-30.256	-30.217	-30.237
36	5.397	-31.221	-31.183	-31.203
37	5.537	-32.201	-32.162	-32.183
38	5.6654	-33.1	-33.061	-33.081
39	5.7938	-33.998	-33.959	-33.979
40	5.9314	-34.961	-34.923	-34.943
41	6	-35.441	-35.403	-35.423
42	6.1308	-36.36	-36.321	-36.342
43	6.2617	-37.273	-37.234	-37.254
44	6.3831	-38.123	-38.084	-38.104
45	6.5045	-38.973	-38.934	-38.954
46	6.6415	-39.932	-39.893	-39.913
47	6.7681	-40.818	-40.779	-40.799
48	6.8946	-41.704	-41.665	-41.685
49	7	-42.441	-42.402	-42.422
50	7.1281	-43.341	-43.302	-43.322
51	7.2562	-44.235	-44.196	-44.216
52	7.3846	-45.133	-45.094	-45.115
53	7.513	-46.032	-45.993	-46.013
54	7.6332	-46.874	-46.835	-46.855
55	7.7535	-47.715	-47.677	-47.697
56	7.8799	-48.6	-48.561	-48.582
57	8	-49.441	-49.402	-49.422
58	8.1221	-50.298	-50.26	-50.28
59	8.2442	-51.15	-51.111	-51.132
60	8.382	-52.115	-52.076	-52.096
61	8.5086	-53.001	-52.962	-52.983
62	8.6352	-53.888	-53.849	-53.869
63	8.7552	-54.727	-54.688	-54.709
64	8.8751	-55.567	-55.528	-55.548
65	9	-56.441	-56.402	-56.422
66	9.1304	-57.357	-57.318	-57.338
67	9.2608	-58.267	-58.228	-58.248
68	9.397	-59.22	-59.181	-59.201
69	9.5361	-60.194	-60.155	-60.175
70	9.6644	-61.092	-61.053	-61.073
71	9.7927	-61.99	-61.951	-61.971
72	9.9137	-62.837	-62.798	-62.818
73	10	-63.441	-63.402	-63.422
74	10.132	-64.366	-64.327	-64.347
75	10.263	-65.285	-65.246	-65.266
76	10.401	-66.251	-66.212	-66.232
77	10.539	-67.216	-67.177	-67.197
78	10.679	-68.194	-68.155	-68.175
79	10.807	-69.093	-69.054	-69.075
80	10.936	-69.993	-69.954	-69.974
81	11	-70.441	-70.402	-70.422
82	11.129	-71.344	-71.305	-71.326
83	11.257	-72.242	-72.203	-72.223
84	11.386	-73.14	-73.101	-73.122
85	11.514	-74.039	-74	-74.02
86	11.635	-74.886	-74.848	-74.868
87	11.756	-75.734	-75.695	-75.715
88	11.883	-76.624	-76.585	-76.605
89	12	-77.441	-77.402	-77.422
90	12.07	-77.934	-77.895	-77.915
91	12.14	-78.421	-78.382	-78.402
92	12.245	-79.156	-79.117	-79.137
93	12.384	-80.129	-80.09	-80.111
94	12.51	-81.014	-80.975	-80.995
95	12.637	-81.899	-81.86	-81.88
96	12.761	-82.77	-82.731	-82.751
97	12.886	-83.641	-83.602	-83.622
98	13	-84.441	-84.402	-84.422
99	13.131	-85.359	-85.32	-85.34
100	13.261	-86.271	-86.232	-86.252
101	13.413	-87.329	-87.29	-87.31
102	13.564	-88.389	-88.35	-88.37
103	13.722	-89.492	-89.453	-89.474
104	13.889	-90.667	-90.628	-90.648
105	14	-91.441	-91.402	-91.422

Simulation Video - https://drive.google.com/file/d/1l5u9c-jKBDz8q6VPgTQKmkNjIquPgKXZ/view?usp=sharing

Tabulation:

Solution Parameters	Max. Equivalent Stress (MPa)	Max. Equivalent Plastic Strain (mm/mm)	Max. Directional Deformation (mm)
Results	2489.1	1.1143	-91.422

Explanation:

Since, the material we have chosen is Copper Alloy NL which is a non-linear material and it doesn’t have a Tensile Yield Strength value and the strain-stress curve is linear after a particular value. So, it doesn’t break and we have got the values for the required solution parameters with the tabulation. We have also given the values accordingly in tabular data so that the workpiece has been displaced by 90 mm and it is proved so by selecting the bottom tip of the workpiece to show that the material displaced to a value of 91.422 mm.

Rolling Operation

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