Structural analysis of Rolling operation using ANSYS Workbench

AIM: To perform structural analysis on rolling operation of copper using ANSYS Workbench.

PROCEDURE: The model was initially imported into ANSYS as shown below:

The length of the workpiece was increased by 60 mm and the width decreased by 8 mm on both sides. The final geometry is shown below:

The rollers were assigned structural steel and the workpiece was given as Copper NL alloy. The mesh of the geometry is given below:

The two cylinders were given as revlute joints and the contact between the rollers and the workpiece is shown below:

A frictional contact was given with coefficient of 0.1 and other properties are shown below:

The displacement of 90 mm was given to the workpiece as shown below:

The rollers were given rotational boundary conditions as shown below:

The simulation was solved and the stress contour is given below:

A maximum stress of 3049 MPa was observed and the stress variation with time is plotted below:

The plastic strain contour is given below:

A maximum plastic strain of 1.34 was observed and its variation with time is plotted below:

The deformation contour in lateral direction (z-direction) is given below:

Maximum deformation of 5.52 mm was observed in lateral direction. The workpiece displacement at the bottom was observed separately to ensure that it was displaced by 90 mm and it is shown below:

From the above deformation contour, it can be verified that the workpiece has been displaced by 90 mm as given in the input.

CONCLUSION: The structural analysis of rolling operation was successfully performed and the results were discussed quantitatively.