Rolling operation

AIM:

• To perform rolling analysis of copper work piece and obtain the desired output results.

OBJECTIVES OF THE PROJECT:

• To increase the length of the work piece and reduce the width in space claim.
• To add copper alloy NL material to the engineering data.
• To insert the contacts for the wheel and the work piece.
• To insert the work piece movement between the rollers.
• To insert the rotation for the wheels.
• To mesh the rollers and the work piece.
• To evaluate the stress and deformation in the work piece.

PROCEDURE:

• OPEN WORKBENCH21 > NEW PROJECT > STATIC STRUCTURAL.
• This will start a new static structural project.
• Rename the project as Rolling copper.
• Go to ENGINEERING DATA > EDIT > GENERAL MATERIALS NL > COPPER ALLOY NL > ADD.
• This will add the copper alloy NL to the material data.
• Then double click on Geometry. This will open the Spaceclaim.
• In Space claim use Pull option to extend the work piece length by 60mm and decrease its both sides by 8mm.
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• The geometry for the case is done and exit the Spaceclaim.
• Then double click on Model. This will open Mechanical module.
• Now, rename the geometry as roll1, roll2 and work piece.
• Then assign copper alloy NL to work piece.
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• Then go to CONTACTS > FLIP > RENAME BASED ON DEFINITION.
• Define the contact faces correctly for both the contacts.
• Select both the contacts and define TYPE = FRICTIONAL > FRICTIONAL COEFFICIENT = 0.2 > FORMULATION = AUGMENTED LAGRANGE > NORMAL STIFFNESS = FACTOR > 0.1 > UPDATE STIFNESS = EACH ITERATION > INTERFACE TREATMENT = ADD OFFSET, RAMPED EFFECTS.
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• INSERT > JOINTS > BODY-GROUND > TYPE = CYLINDRICAL > SCOPE > INNER FACE OF ROLLER.
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• Similarly, define cylindrical joint for roller 2.
• Now, go to MESH > INSERT > SIZING > SCOPE = WORK PIECE > ELEMENT SIZE = 2MM > GENERATE MESH.
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• The mesh will be generated on the model.
• Then go to STATIC STRUCTURAL > ANALYIS SETTINGS > NO OF STEPS = 14 > LARGE DEFLECTION = ON > STABILIZATION = CONSTANT > ENERGY DISSIPATION RATIO = 0.1.
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• Go to STATIC STRUCTURAL > INSERT > DISPLACEMENT > DEFINE BY = COMPONENTS > GEOMETRY > WORK PIECE > MAGNITUDE = Y TABULAR and insert the following values.
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• Then, go to SOLUTION > INSERT > JOINT LOAD > JOINT = CYLINDRICAL GROUND TO ROLL1 > TYPE = ROTATION > DOF = Z > MAGNITUDE = TABULAR DATA.
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• Similarly, define rotation for the Roll2.
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• Then, go to SOLUTION > INSERT > STRESS > STRAIN > DEFORMATION.
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• This will set the output results.

RESULTS:

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LEARNING OUTCOMES:

• To add copper alloy NL material.
• To edit Geometry in Spaceclaim.
• To assign material from the material library.
• To define frictional roller contacts.
• To define cylindrical joints.
• To deploy mesh on the geometry.
• To define body sizing.
• To define displacement for the work piece.
• To define rotation for rollers.
• To define output results.

CONCLUSION:

• By performing this project we conclude that, the static analysis on the rolling copper workpiece is performed and edge of the workpiece is displaced by 90mm.