OBJECTIVE:

In this process, the wire is bent by the force applied on it due to the rotation of lever.

a.Copper Sheet rolling is displaced by 90 mm

b.Rolling wheel is given with joint loading.

Due to the above motion, the wire is deformed and it will follow the path of the wheel and bends.

NON-LINEAR MATERIAL PROPERTY:

The sheet rolling operation is performed above its yield strength to get a permanent deformation. Hence, we go for Nonlinear analysis by providing the Non-linear material property of copper.

ANALYSIS IN STEPS

Since, deformation force applied on sheet is so high we have to apply it step by step but not directly

CASE SET UP & SIMULATION:

CONTACTS

In this simulation there are in total three bodies:

However, only two of those is required to be defined properly for the simulation.

1.Contact between Sheet & wheel-1 – Frictional

2.Contact between Sheet & Wheel-2 – Frictional

Contact Settings :

a.Co-efficient of friction – 0.2

b.Formulation – Augmented LaGrange.

c.Normal Stiffness – Factor

d.Normal Stiffness' factor – 0.1

e.Upgrade Stiffness – Each Iteration

f.Interference Treatment – Add offset & Ramped effects

JOINTS:

A Revolute joint is provided at the lever as it can be provided with the angular deformation in degree using the joint loads.

JOINT SETTINGS :

A.Connection type -Body to ground : Cylindrical Joint.

B.Behavior – Rigid

ANALYSIS SETTINGS:

NUMBER OF STEPS:

This is the load application steps. So here a total deformation of 195 Deg angle is provided in 8 steps .

Large Deflection = ON

Stabilization = Constant

Energy Dissipation = 0.1

Physically, It means that if the solution is not converged in 25 iteration, then abort the operation

LOADS:

DISPLACEMENT LOAD :

On the sheet in the longitudinal axis the displacement of 90mm is divided in 14 Different steps.

CYLINDERICAL LOAD :

The Cylindrical Joint is given with 195 Deg rotation in 14 Different sets for both the wheels with opposite direction.

RESULTS & DISCUSSION:

The post-processing is done for :

1. Deformation in Z - axis = 7 mm (max)

2. Deformation in axial movement = 90 mm

3. Plastic Strain = 0.025 mm/mm