Week 4- Rolling operation

Objective of challenge: To perform the simulation of Sheet rolling operation on a work-piece made of copper. Requirements to setup of work-piece before simulation is, Increase the length of the workpiece by 60mm and decrease its size on both sides by 8mm. Run the simulation for 14 steps by providing small and random values for the displacement. Finally find out Equivalent stress for the whole setup, Equivalent Plastic strain for the workpiece, Directional Deformation in the Z axis for the workpiece and to prove that the workpiece is displaced by 90mm.

Simulation setup configuration as follows:

1. Part names are specified as

2. Material applied for wheel 1 and 2 is "Structural steel" and for work-piece is "Copper alloy NL".

3. Two Connections configured, Frictional - work piece to wheel 1 and Frictional - work piece to wheel 2.

3. Mesh size applied for 2 wheels is 7mm and work-piece is 4mm.

5. Analysis settings configured as shown in below image.

6. Displacement setup for 14 steps to work-piece along Y-axis negative direction, configured as shown in below image.

7. Joint rotation setup for 14 steps to wheel 1, configured as shown in below image.

8. Joint rotation setup for 14 steps to wheel 2, configured as shown in below image.

Simulation results tabulated as follows:

Description	Simulation Results
Equivalent stress for the whole setup	Max 1725.5 Mpa
Equivalent Plastic strain for the workpiece	Max 1.1064 mm
Directional Deformation in the Z axis for the workpiece	Max 6.493 mm
Workpiece displacement	85.987 mm