Simulation of The Rolling Operation on A Workpiece made of Copper using ANSYS WorkBench.

Objective: Simulate the rolling operation on a workpiece made of copper.

Find out the:

1. Equivalent stress for the whole setup.
2. Equivalent Plastic strain for the workpiece.
3. Directional Deformation in the Z-axis for the workpiece.
4. Prove that the workpiece has displaced by 90mm.

Model given:

After increasing the length by 60 mm and reduced the width by 8mm from each side:

Material setup:

Connections:

Joints:

Meshing stats & model:

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Analysis setting:

Tabular details:

Displacement of Copper sheet: (90mm) Rotation of both wheels

a b c

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Solutions:

Equivalent Stress:

Directional deformation of the workpiece in Z direction:

Strain at workpiece:

Equivalent strain graph:

Proof of workpiece movement of 90mm in Y direction in the given time step:

Results and conclusion:

Equivalent Stress (MPa)	3287.9
Strain at workpiece (mm/mm)	0.030
Directional Deformation (mm)	6.68

• Copper is well-known to be a soft, malleable metal. Copper alloys, however, offer a wide variety and combination of
  mechanical properties that reflect a degree of adaptability not available in other alloy systems. Copper and high copper
  alloys are used extensively for cables, wires, electrical contacts, and a multitude of other components that carry electrical
  current.
• Copper alloys are primarily strengthened by cold work or by solid solution additions that enhance *strain hardening.
• Copper alloys can form protective films and show higher resistance to corrosion than in natural water.
• They have excellent electrical and thermal conductivities, exhibit good strength and formability, have outstanding resistance to
  corrosion and fatigue, and are generally nonmagnetic.

*Strain Hardening is when a metal is strained beyond the yield point. Increasing stress is required to produce additional plastic deformation and the metal apparently becomes stronger and more difficult to deform.