Week 4- Rolling operation

Rolling Operation in Ansys

Objective

Simulate a rolling operation of the given workpiece ( Copper ) and infer the results.

Briefing

The model consists of 3 parts - 2 rollers and the workpiece.

For case 1 the workpiece with 90mm is used and for case 2 with a length of 150mm is used.

Width of the workpiece with reduced by 2mm for case 2. ( Operations performed in Spaceclaim).

Procedure and Setup

• Wheels are assigned with structural steel and the workpiece is given copper alloy non - linear.

Contact Definition: Frictional contacts are defined between workpiece and wheel contact surfaces. 

With Frictional Coefficent = 0.2;

Augmented Lagrange Formulation;

Normal Stiffness behavior factor = 0.1;

Interface Treatment as Add offset, ramped effects

Joints Definition: both the wheels are given cylindrical joints 

Meshing - Default Mesh parameter used with element size as 3mm.

Boundary Conditions

Displacement is given to the workpiece on the z-axis, in 15 load steps.

The wheels are given rotation in degrees in opposite directions in order to pull the workpiece.

Analysis Settings: Program Controlled Approach is used for this case and large deflections are turned on.

Results and Conclusion:

Cases / Parameters	Equivalent stress for the whole setup ( MPa)  (Max)	Equivalent Plastic strain for the workpiece (Max)	Directional Deformation in the Z-axis for the workpiece ( Max)
Case 1  ( 90 x 10 mm)	8135.9 MPa	3.0073 mm/mm	7.921 mm
Case 2 ( 150 X  8 mm)	8366.2 MPa	2.1415 mm/mm	6.4389 mm

• The workpiece has undergone plastic deformation (Yield stress of Copper = 280 MPa) and maximum stress is developed in the workpiece. 
• In case 1 has undergone more plastic strain than case 2.
• In both cases, the workpiece is displaced by 90mm.