Week 4- Rolling operation

Aim: In this simulation we will be looking at the stress and plastic strain developed in a copper slab as it undergoes rolling. We will also be looking at the change in width as well as the distance travelled by the piece.

Setup: We begin by assigning the workpiece as Copper Alloy Non-linear and redefining the contact regions to include the entire slab.

The contact is frictional with a coefficient of 0.2. The simulation is formulated using augmented lagrange with a normal stiffness factor of 0.1 on each iteration.

We will further define the joints on each roller as cylindrical and conduct the simulation over a period of 14 steps. Large Deflection is turned on and constant stabilization with energy dissipation of factor 0.1.

The Slab is displaced by 90mm in the negative y-axis.

Both rollers have rotation along the z-axis with equal but opposite incremental gains of 15 deg per step.

Results:

Maximum Stress developed in the entire system is 1824.8MPa

Maximum Plastic Strain developed in the workpiece is 1.1091 mm/mm

Maximum Deformation in z axis for the workpiece is 8.1853mm

Distance travelled by the workpiece along y axis is 90.547mm