Week 4- Rolling operation
Objective: This challenge aims to perform the Rolling operation on the copper sheet as per the given requirements and find out the Equivalent Stress of the assembly, Equivalent Plastic Strain of the workpiece, and Deformation in the Z direction.
Requirement:
1) Modify the dimensions ( i.e., increase the workpiece length by 60 mm and decrease the thickness by 8 mm on both sides.)
2) Run the simulation for14 steps.
Geometry: Import the geometry in DesignModular or in Spaceclaim and change the dimension as per given above.
Modified geometry is shown in fig. below.
Material: We have used Structural Steel for rollers and copper alloy NL for workpiece.
Properties of these materials are given below.
Structural Steel:
Copper Alloy NL:
Contacts:
Frictional Contact between Workpiece and Roller:
Coefficient of friction=0.2
Formulation: Augmented Lagrange.
Interface Treatment: Add offset, Ramped Effect.
Joints: We have defined the body-to-ground Revolute joints for both rollers.
Mesh:
We have applied the 3 mm mesh to the workpiece.
Analysis Settings:
We are running this simulation in 14 steps with the following analysis settings.
Boundary Conditions:
We have applied the Rotation to both the rollers in 14 steps.
We have given the displacement to the workpiece in 14 steps.
Results:
Animation:
1) Equivalent Stress:
2) Equivalent Plastic Strain in Workpiece:
3) Directional Deformation In Z direction for Workpiece:
4) To Prove that the workpiece is moved by 90 mm we have to find the directional deformation in the Y direction for the Workpiece.
Conclusion:
We have successfully simulated the rolling operation of the copper sheet and findings are given below.
| Max. Equivalent Stress in MPa | 2751.3 |
| Max. Plastic Strain in Workpiece ( in mm/mm) | 0.9474 |
| Max. Directional Deformation in Z- Direction for Workpiece ( in mm) | 3.9708 |
| Max. Directional Deformation in Y- Direction for Workpiece ( in mm) | 86.105 |
From the Directional Deformation in the Y direction, we have seen that the workpiece is displaced by 86.105 mm.