Week 4- Rolling operation

AIM:

• To perform a rolling operation on a given copper workpiece.
• To find out directional deformation, equivalent stress, the equivalent plastic strain on the workpiece and to prove that the workpiece is displaced by 90mm during the simulation.

PROCEDURE:

• Open ansys workbench and drag and drop a static structural analysis standalone system into the workspace.
• Rename it as copper rolling.

• Save the project with the required name.
• Double click on engineering data and go to engineering data sources and add COPPER ALLOY NL material to the library.
• Right-click on geometry and import geometry from the file location.

• Right-click on geometry and edit using space claim make the necessary geometric repairs as mentioned i.e., increase the length of the workpiece by 60 mm and decrease the width of workpiece on both sides by 8mm using pull option.

LENGTH INCREASED BY 60mm.

FINAL GEOMETRY AFTER CHANGING THE DIMENSIONS AS MENTIONED.

• Close SpaceClaim.
• Update the project.
• Open ansys mechanical and rename the parts as required.
• Change the workpiece material to copper.

• Goto connections and contacts rename the contacts based on the definition and flip contact and target bodies.

• Select both the contacts and change the contact type to frictional with a coefficient of friction value of 0.1.
• Change the formulation to augmented Lagrange.
• Change the normal stiffness factor to 0.1
• Change the update stiffness to each iteration. And interface treatment to add offset ramped effects.

• Create cylindrical joints to the rollers and change the orientation of the Z-axis.

• Now mesh the component using default mesh size and insert body sizing with an element length of 4mm.

• Generate mesh.

• The above picture represents mesh metrics it gives a clear picture of element quality and type of elements used for the simulation.
• Now change the analysis settings.
• Turn large deflection on and change the number of steps to 15.
• Select all the 15 steps, Under non-linear controls change the stabilization to constant and energy dissipation ratio to 0.1.

• Apply joint load for cylindrical joints and displacement in negative Y-direction in which the workpiece progresses towards roller during the simulation for the workpiece in tabular data as below.

• List the outputs required from the simulation and simulate the model to obtain results.

RESULTS:

EQUIVALENT STRESS:

EQUIVALENT PLASTIC STRAIN:

DIRECTIONAL DEFROMATION OF WORKPIECE ALONG Y-AXIS:

DIRECTIONAL DEFORMATION OF WORKPIECE ALONG Z-AXIS:

CONCLUSIONS:

• The rolling operation on a workpiece made of copper is performed successfully using ansys workbench.
• Equivalent Plastic strain and equivalent stress in the workpiece are found successfully from the simulation.
• Directional Deformation in the Z-axis for the workpiece is obtained.
• It is proved that the workpiece is displaced by 90 mm during the simulation.