Week 4- Rolling operation

COPPER ROLLING OPERATION

AIM:

IN THIS ANALYSIS, WE NEED TO FIND THE PLASTIC DEFORMATION OF THE COPPER ALLOY MATERIAL (WORKPIECE) AND TO PROVE THAT THE DISPLACEMENT OF THE WORKPIECE HAS BEEN DISPLACED TO 90mm.

MODEL:

THE MODEL CONSISTS OF TWO WHEEL AND THE WORKPIECE,

MATERIAL:

THERE ARE TWO DIFFERENT MATERIALS ALLOTED FOR THE SIMULATION OF THE COPPER ROLLING OPERATION, WHERE THE WORKPIECE HAS BEEN ALLOTED WITH THE COPPER ALLOY (WITH NON-LINEARITY). AND THE WHEELS HAVE BEEN ALLOTED WITH THE STRUCTURAL STEEL.

STRUCTURAL STEEL :

COPPER ALLOY NL :

CONTACTS:

THERE ARE TWO CONTACTS IN THE MODEL, THE WORKPIECE AND THE ROLLER, THE UPPER FACE OF THE WORKPIECE AND THE ROLLER 1 AND THE LOWER FACE OF THE WORKPIECE AND THE ROLLER 2. BOTH THESE CONTACTS ARE FRICTIONAL WITH CO-EFFICIENT OF FRICTION OF 0.2 AND THE FORMULATION IS SET OT AUGMENTED LAGRANAGE AND THE BEHAVIOUR SET TO ADD OFFSET AND RAMPED EFFECTS.

CONTACT 1: WHEEL1 AND THE UPPER SURFACE OF THE WORKPIECE

CONTACT 2 : LOWER SURFACE OF THE WORKPIECE AND THE WHEEL 2

JOINTS:

THE MODEL HAS TWO JOINT LOADS FOR THE TWO DIFFERENT ROLLER ONE WITH THE ROTATION WITH CLOCKWISE DIRECTION AND THE OTHER ROLLER WITH THE ANTI-CLOCKWISE DIRECTION.

JOINT 1 : CLOCKWISE ROTATION - WHEEL 1 :

JOINT_2 : ANTI-CLOCKWISE_ROTATION_ WHEEL 2:

MESH:

THE MESH HAS BEEN SET TO GRID DEPENDENCY TEST FOR THE ROLLER USING ADAPTIVE MESH SIZE AND THE WORKPIECE MESH SIZE HAS BEEN REFINED TO 2mm.

ANALYSIS SETTINGS:

THE ANALYSIS HAS BEEN CARRIED OUT IN 14 STEPS ON AUTO- TIMING, SINCE THE ANALYSIS IS AN NON-LINEAR ANALYSIS, THE NON- LINEAR CONTROLS HAS BEEN MODIFIED, WHERE THE ENERGY DISSIPATION – RATIO HAS BEEN SET TO 0.1 CONSTANT VALUE.

DISPLACEMENT :

JOINT-LOAD1:

JOINT-LOAD2:

SIMULATION :

THE SIMULATION IS RUNNED FOR 14 STEPS WITH RANDOM DISPLACEMENT VALUES ,

DIRECTIONAL DEFORMATION:

THE DEFORMATION OF THE WORKPIECE IN THE Z-AXIS HAS BEEN SIMULATED AND THE RESULTS HAVE BEEN ATTACHED .

DIRECTIONAL DEFORMATION 2:

THE DEFORMATION OF THE WORKPIECE , IN THE Y-DIRECTION HAS BEEN SIMULATED AND ATTACHED .

EQUIVALENT STRESS:

THE EQUIVALENT STRESSS OF THE ENTIRE MODEL HAS BEEN CALCULATED AND SIMULATED AND ATTACHED .

EQUIVALENT PLASTIC STRAIN:

CONTACT:

PRESSURE:

FRICTIONAL STRESS:

MOMENT REACTION:

FORCE CONVERGENCE :

RESULT:

THUS WE PROVED THAT , THE MODEL HAS BEEN DISPLACED TO 90mm.