Challenge

Simulation of Rolling operation using Ansys-Workbench

AIM: The aim of this Simulation is to see the distribution of stress for the given workpiece undergoing Rolling Operation.

OBJECTIVES:

  1. To increase the length of the Workpiece by 60mm and decrease the size on both sides by 8mm.
  2. To ensure that the workpiece is displaced by 90mm.

PROCEDURE:

Once we open ANSYS-WORKBENCH we will have to first select the material that we need for this simulation. In this Simulation, we will be using Structural Steel for the Rollers and Copper Alloy NL for the workpiece.

After adding the materials from the Engineering data we should upload the model in space claim so that we can perform the given design changes.

The length of the workpiece will be increased by 90mm and the sides will be reduced by 8mm from each side.

Once all the design changes are done the model will look like this.

The contacts between the roller and the Workpiece will be assigned with frictional contacts with a frictional coefficient of 0.2. The formulation used will be Augmented Lagrange.

The Rollers will be provided with Revolute joints so that the rollers will rotate along the Z-Direction. We can also give other joints like a cylindrical joint.

Now we will be Meshing the Assembly. A body sizing of 2mm will be given to the Workpiece as it is an important region here and the rest of the assembly is meshed with default parameters.

The Element size is 1579 and the Node size is 9057.

Once the meshing is done we can provide the loading conditions.

Both the Rollers will rotate in the opposite direction in 14 steps totally rotating for an angle of 150'. The workpiece will move for a length of 90mm along the negative y-direction.

RESULTS:

EQUIVALENT STRESS:

Table:

Time Minimum(Mpa) Maximum(Mpa) Average(Mpa)
0.2 6.09E-05 552.74 29.384
0.4 2.56E-08 662.02 40.992
0.505 2.04E-09 625.35 45.382
0.61 5.94E-10 647.92 48.598
0.7675 9.99E-10 716.94 56.637
0.925 1.55E-09 825.54 65.763
1 1.98E-09 917.56 71.192
1.2 3.39E-09 976.45 82.378
1.27 4.81E-09 998.23 86.912
1.34 5.33E-09 1010.8 90.224
1.445 5.67E-09 1023.9 94.941
1.6025 7.94E-09 1042.9 103.56
1.6852 9.59E-09 1040 107.82
1.7679 1.11E-08 1046.4 112.32
1.8919 1.20E-08 1116.3 118.18
2 1.43E-08 1175.9 123.29
2.07 1.83E-08 1232.8 130.22
2.14 2.41E-08 1276.7 137.27
2.245 2.89E-08 1286.5 146.64
2.35 3.92E-08 1308.1 155.6
2.3945 4.36E-08 1364.9 158.87
2.4389 5.09E-08 1410.4 161.86
2.5056 5.91E-08 1459.2 166.77
2.5723 6.83E-08 1508.5 170.94
2.6724 8.48E-08 1532.2 178.85
2.7158 9.68E-08 1522.9 181.34
2.7591 1.14E-07 1519.1 184.55
2.8242 1.33E-07 1555.6 188.88
2.9218 1.59E-07 1606.5 195.85
3 1.93E-07 1673.6 202.33
3.07 2.40E-07 1758 209.06
3.14 3.14E-07 1744.1 214.44
3.242 3.72E-07 1795.1 222.86
3.2828 4.15E-07 1815.8 226.69
3.3236 4.71E-07 1834.7 229.99
3.3847 5.64E-07 1861.1 235.35
3.4765 6.11E-07 1895.8 242.88
3.5806 7.87E-07 1949.2 251.72
3.6828 1.06E-06 1997.1 260.85
3.785 1.20E-06 2037.3 268.33
3.8894 1.63E-06 2069.3 277.31
3.9899 2.15E-06 2106.1 284.96
4 2.25E-06 2110.6 285.7
4.07 2.12E-06 2140.5 291.18
4.14 3.25E-06 2163 295.56
4.2314 4.01E-06 2187.2 302.03
4.3227 4.70E-06 2207 308.47
4.4204 5.60E-06 2244.4 314.65
4.5271 7.43E-06 2275 321.71
4.6143 9.02E-06 2292.4 327.09
4.7015 1.05E-05 2302.8 332.46
4.806 1.39E-05 2335.1 338.51
4.9054 1.70E-05 2356.2 343.46
5 2.00E-05 2368.7 348.55
5.07 2.50E-05 2389.3 354.6
5.14 3.33E-05 2407.2 357.89
5.2255 3.89E-05 2423.7 361.98
5.3109 4.44E-05 2434.7 366.29
5.414 5.63E-05 2446.7 373.47
5.4993 6.69E-05 2466.2 377.21
5.5846 7.82E-05 2479.5 381.7
5.684 1.02E-04 2487.3 386.7
5.7849 1.22E-04 2503.4 391.76
5.8737 1.46E-04 2519 397.02
5.9625 1.84E-04 2528.1 400.93
6 2.11E-04 2530.6 403.01
6.07 2.34E-04 2538.3 408.47
6.14 3.01E-04 2551 411.47
6.2338 3.56E-04 2562.5 415.6
6.3277 4.29E-04 2567.7 420.24
6.4127 5.18E-04 2571.5 424.74
6.4977 6.07E-04 2585.2 428.57
6.5963 7.69E-04 2593.7 433.05
6.6968 6.44E-04 2598.9 438.14
6.7962 1.11E-03 2615.8 443.31
6.8955 1.15E-03 2624.9 448.03
6.9958 8.62E-04 2625.3 452.98
7 7.32E-04 2626.6 453.65
7.07 9.29E-04 2640.9 458.52
7.14 4.47E-04 2648.4 461.22
7.2423 1.25E-03 2654.5 465.02
7.3251 7.55E-04 2653.9 469.41
7.4078 8.98E-04 2667.2 472.91
7.4905 7.71E-04 2675.2 476.5
7.5795 7.61E-04 2678.4 480.89
7.6684 6.44E-04 2670.8 486.08
7.7655 1.04E-03 2683.2 489.86
7.8713 1.24E-03 2688.6 494
7.9357 3.69E-04 2677.3 497.27
8 8.74E-04 2688.6 500.27
8.07 5.93E-04 2697.2 504.41
8.14 6.06E-04 2701.5 507.2
8.2246 8.62E-04 2699.2 510.64
8.3093 2.91E-04 2714 515.13
8.4074 4.00E-04 2723.7 519.32
8.4971 3.04E-04 2726.4 523.26
8.5867 2.31E-04 2722.5 528.43
8.6847 4.20E-04 2734.4 531.97
8.778 2.73E-04 2739.9 535.63
8.8714 6.11E-04 2720.3 540.41
8.9682 4.13E-04 2733.7 543
9 5.62E-04 2737.2 544.41
9.07 1.63E-03 2742.1 540.31
9.14 1.22E-03 2741.9 537.84
9.2212 1.17E-03 2746.9 537.1
9.3062 1.04E-03 2757.3 538.41
9.3918 1.63E-03 2763.6 541.59
9.4775 1.39E-03 2744.3 546.98
9.5632 5.69E-04 2756.9 551.4
9.6538 4.93E-04 2767 557.04
9.7294 3.91E-04 2746.4 562.59
9.8051 6.20E-04 2758.4 567.4
9.8944 1.06E-03 2770.2 572.93
9.9472 1.01E-03 2774.9 577.05
10 1.03E-03 2760.3 581.5
10.061 1.03E-03 2778.1 585.77
10.122 1.10E-03 2788.7 596.89
10.191 9.92E-04 2791.2 607.86
10.25 9.84E-04 2791.3 617.75
10.309 1.27E-03 2806 626.02
10.378 8.81E-04 2814.8 633.9
10.448 3.35E-04 2816.8 642.05
10.509 6.53E-04 2808.8 650.11
10.569 5.30E-04 2822 656.31
10.64 9.96E-04 2829.2 663.16
10.711 1.61E-03 2830.1 671.5
10.781 1.60E-03 2845.2 679.76
10.85 1.39E-03 2857.6 686.78
10.92 7.76E-04 2861.5 694.03
10.96 1.24E-03 2864.8 698.97
11 1.46E-03 2876.8 704.18
11.07 5.80E-04 2892.1 700.69
11.131 1.60E-03 2897.5 714.71
11.192 1.68E-03 2898.5 720.48
11.251 1.70E-03 2909.4 727.46
11.31 1.74E-03 2922.8 733.61
11.379 1.81E-03 2930.4 739.23
11.441 1.86E-03 2933 744.59
11.503 1.93E-03 2951.9 751.05
11.571 2.01E-03 2967.7 758.26
11.638 2.12E-03 2975.4 763.82
11.708 2.21E-03 2992.8 769.46
11.767 2.42E-03 3009.9 775.46
11.826 2.61E-03 3023.6 781.59
11.895 2.70E-03 3032.5 787.24
11.956 2.48E-03 3034.2 792.21
12 2.35E-03 3037 795.91
12.067 1.83E-03 3053.6 793.09
12.126 2.47E-03 3062.6 805.89
12.185 2.19E-03 3065.5 810.46
12.252 1.57E-03 3062.7 815.19
12.311 1.34E-03 3077.4 820.09
12.369 1.32E-03 3087.8 824.59
12.435 1.45E-03 3092.3 828.74
12.502 1.38E-03 3091.1 832.94
12.572 1.28E-03 3109.4 837.28
12.645 1.19E-03 3120.8 841.22
12.717 1.16E-03 3142.8 844.16
12.793 1.10E-03 3187.4 846.8
12.872 1.06E-03 3228.4 850.18
12.955 1.13E-03 3259.9 851.57
13 2.34E-02 3276.2 852.77
13.07 2.36E-03 3285.2 841.12
13.14 2.00E-03 3293.3 845.49
13.241 2.57E-03 3300.7 843.36
13.361 2.58E-03 3327.5 840.61
13.48 2.57E-03 3361.5 836.94
13.625 2.39E-03 3393.3 835.04
13.798 2.39E-03 3446.5 832.73
13.899 2.28E-03 3467.4 829.24
14 2.16E-03 3502.1 827.98

The maximum stress value reached is 3502 Mpa.

PLASTIC STRAIN:

Plastic Strain Table

Time Minimum(mm/mm) Maximum(mm/mm) Average(mm/mm)
0.2 0 3.50E-02 7.98E-04
0.4 0 8.04E-02 3.67E-03
0.505 0 9.41E-02 4.92E-03
0.61 0 0.11513 6.48E-03
0.7675 0 0.17034 1.07E-02
0.925 0 0.24258 1.66E-02
1 0 0.29635 2.09E-02
1.2 0 0.36406 2.84E-02
1.27 0 0.38664 3.11E-02
1.34 0 0.40932 3.39E-02
1.445 0 0.44664 3.80E-02
1.6025 0 0.49842 4.43E-02
1.6852 0 0.5238 4.76E-02
1.7679 0 0.54842 5.10E-02
1.8919 0 0.58303 5.61E-02
2 0 0.61047 6.05E-02
2.07 0 0.64172 6.60E-02
2.14 0 0.68005 7.13E-02
2.245 0 0.72912 7.94E-02
2.35 0 0.77373 8.73E-02
2.3945 0 0.79209 9.07E-02
2.4389 0 0.80914 9.41E-02
2.5056 0 0.83467 9.92E-02
2.5723 0 0.86304 0.10425
2.6724 0 0.90256 0.1117
2.7158 0 0.91917 0.11496
2.7591 0 0.93492 0.11826
2.8242 0 0.95713 0.12317
2.9218 0 0.98615 0.1303
3 0 1.0072 0.13606
3.07 0 1.0304 0.1412
3.14 0 1.0528 0.14659
3.242 0 1.0811 0.15409
3.2828 0 1.0918 0.15714
3.3236 0 1.1013 0.16014
3.3847 0 1.1141 0.16466
3.4765 0 1.1302 0.17141
3.5806 0 1.1522 0.17894
3.6828 0 1.1729 0.18634
3.785 0 1.1894 0.19381
3.8894 0 1.2051 0.20132
3.9899 0 1.2249 0.20858
4 0 1.2269 0.20933
4.07 0 1.238 0.21428
4.14 0 1.2466 0.21952
4.2314 0 1.2557 0.22623
4.3227 0 1.2721 0.23292
4.4204 0 1.286 0.24006
4.5271 0 1.2965 0.24777
4.6143 0 1.3023 0.25414
4.7015 0 1.3149 0.26053
4.806 0 1.3261 0.26807
4.9054 0 1.333 0.27523
5 0 1.3429 0.28213
5.07 0 1.3513 0.28706
5.14 0 1.3572 0.2924
5.2255 0 1.3624 0.29871
5.3109 0 1.3658 0.30504
5.414 0 1.3742 0.31254
5.4993 0 1.3803 0.31879
5.5846 0 1.3844 0.32512
5.684 0 1.3924 0.33236
5.7849 0 1.4005 0.33967
5.8737 0 1.4053 0.34625
5.9625 0 1.4109 0.35272
6 0 1.415 0.3555
6.07 0 1.4204 0.36039
6.14 0 1.4243 0.36579
6.2338 0 1.4276 0.37279
6.3277 0 1.4291 0.37965
6.4127 0 1.4306 0.38594
6.4977 0 1.4345 0.39228
6.5963 0 1.4369 0.3995
6.6968 0 1.4441 0.40683
6.7962 0 1.449 0.41415
6.8955 0 1.4515 0.42141
6.9958 0 1.4558 0.42871
7 0 1.4562 0.42903
7.07 0 1.4599 0.43403
7.14 0 1.4621 0.43942
7.2423 0 1.4638 0.447
7.3251 0 1.4665 0.45314
7.4078 0 1.4703 0.45936
7.4905 0 1.4725 0.46547
7.5795 0 1.4735 0.47201
7.6684 0 1.4738 0.47863
7.7655 0 1.4769 0.48579
7.8713 0 1.4784 0.49345
7.9357 0 1.4803 0.49823
8 0 1.4835 0.50306
8.07 0 1.4855 0.50797
8.14 0 1.4866 0.51336
8.2246 0 1.4879 0.51968
8.3093 0 1.492 0.52605
8.4074 0 1.4945 0.53329
8.4971 0 1.4954 0.5399
8.5867 0 1.4957 0.54658
8.6847 0 1.4961 0.55381
8.778 0 1.4975 0.56063
8.8714 0 1.4979 0.56754
8.9682 0 1.5008 0.57468
9 0 1.5017 0.57706
9.07 0 1.5028 0.58261
9.14 0 1.5082 0.58867
9.2212 0 1.514 0.59558
9.3062 0 1.5181 0.60272
9.3918 0 1.5204 0.60988
9.4775 0 1.5214 0.61711
9.5632 0 1.5252 0.62428
9.6538 0 1.5278 0.63177
9.7294 0 1.5328 0.63808
9.8051 0 1.5375 0.64442
9.8944 0 1.5408 0.65177
9.9472 0 1.5421 0.65619
10 0 1.5465 0.66059
10.061 0 1.5523 0.66684
10.122 0 1.5568 0.67341
10.191 0 1.5601 0.68067
10.25 0 1.5668 0.6868
10.309 0 1.5725 0.69301
10.378 0 1.5767 0.69997
10.448 0 1.5826 0.70716
10.509 0 1.5894 0.71333
10.569 0 1.5943 0.71949
10.64 0 1.6032 0.72664
10.711 0 1.612 0.73373
10.781 0 1.618 0.74066
10.85 0 1.6225 0.74778
10.92 0 1.6295 0.75476
10.96 0 1.6341 0.75885
11 0 1.638 0.76293
11.07 0 1.6421 0.76991
11.131 0 1.6449 0.77656
11.192 0 1.6523 0.78295
11.251 0 1.658 0.78913
11.31 0 1.6624 0.79532
11.379 0 1.6727 0.80244
11.441 0 1.6799 0.80876
11.503 0 1.6854 0.81501
11.571 0 1.6899 0.82184
11.638 0 1.6983 0.82856
11.708 0 1.7054 0.83536
11.767 0 1.7099 0.84109
11.826 0 1.7134 0.84678
11.895 0 1.7161 0.85334
11.956 0 1.7174 0.85907
12 0 1.718 0.86311
12.067 0 1.7183 0.86895
12.126 0 1.7187 0.8744
12.185 0 1.7203 0.87961
12.252 0 1.7225 0.88539
12.311 0 1.7263 0.89022
12.369 0 1.729 0.89493
12.435 0 1.7309 0.90018
12.502 0 1.7353 0.9052
12.572 0 1.7427 0.91033
12.645 0 1.762 0.91535
12.717 0 1.7805 0.92017
12.793 0 1.7969 0.92494
12.872 0 1.8112 0.92962
12.955 0 1.8236 0.93411
13 0 1.8422 0.93652
13.07 0 1.859 0.93923
13.14 0 1.8783 0.94201
13.241 0 1.9033 0.94571
13.361 0 1.9318 0.94975
13.48 0 1.9682 0.95346
13.625 0 2.0052 0.95758
13.798 0 2.0438 0.96197
13.899 0 2.0601 0.9643
14 0 2.0735 0.96655

The Maximum Plastic strain formed is 2.0735mm/mm

Graph

DIRECTIONAL DEFORMATION ALONG Z-AXIS:

The Directional deformation along the positive and negative z-axis is 5.8322mm

DIRECTIONAL DEFORMATION ALONG Y-AXIS:

The Directional Deformation along the y-axis is 90mm, Here the deformation is calculated from the movement of the selected two surfaces from the tip. So the tip of the Workpiece travels 90mm.

Your portfolio, next

Ship work like this
in your own course.

Talk to a career counsellor

Free 20-minute call. We'll map the right course to where you want to work.

By submitting you agree to our Terms and Privacy Policy.

Talk to a career counsellor

Free 20-minute call. We'll map the right course to where you want to work.

By submitting you agree to our Terms and Privacy Policy.