Week 4- Rolling operation

Objective: To simulate the rolling operation on a copper workpiece by increasing the length of the workpiece by 60mm and decrease its size on both sides by 8mm. To run the simulation for 14 steps and prove that the edge of the workpiece is displaced by 90mm.

Setup:

Engineering data:

Copper alloy NL

Geometry:

• exported file of copper_rolling.stp
• Edit Geometry in spaceclaim: Increase length of workpiece by 60mm and decrease the width by 8mm on each side of workpiece

Model:

Geometry: renamed parts as wheel1, wheel2, workpiece

Material: no change

Coordinate system: no change

Connections:

Contacts:

• Frictional: Workpiece to Wheel1
• Frictional: Workpiece to Wheel2

Joints:

• Cylindrical: Ground to Wheel1
• Cylindrical: Ground to Wheel2

Mesh:

• Body sizing: 3mm to workpiece

Static structural:

• Analysis setting:

1. Number of steps =14
2. Large deflection: on
3. Stabilization: constant
4. Energy dissipation ratio: 0.1
5. Force convergence: On
6. Output controls: All yes

• Displacement:

1. Geometry = 2 faces of workpiece (to avoid slipping)
2. X component = free, Y component = tabular data, Z component = free

• Joint-Rotation:

1. Cylindrical: Ground to Wheel1
2. DOF: Rotation Z
3. Type: Rotation
4. Magnitude: tabular (clockwise)

• Joint-Rotation:

1. Cylindrical: Ground to Wheel2
2. DOF: Rotation Z
3. Type: Rotation
4. Magnitude: tabular (anticlockwise)

Solution:

1. Equivalent stress

2. Equivalent Plastic strain

3. Directional Deformation of Side faces

4. Directional Deformation of face in Y direction