Week 4- Rolling operation

Understanding the effect of copper Rolling Simulation in ansys Workbench

Objective: To study and perform structural analysis of a rolling operations of copper work piece

Simulation Process:

Input Geometry

The CAD model is imported and viewed using space claim, the width of the copper work piece is reduced by 8mm on both sides and length is increased by 60mm

Material:

The two roller are defined as structural steel and the work piece is defined as copper alloy NL

Contacts:

A frictional contact is defined between the upper rollers outside surface and top surface of work piece with a frictional coefficient of 0.2 similar frictional contacts is defined between lower rollers outside surface and bottom surface of work pieces

Contact settings

Formulation- Augmented Lagrange

Normal Stiffness factor-0.1

Update stiffness-Each iterations

Interfaces treatment – Add offset, Ramped Effects

Mesh

The roller are meshed with 5mm. and work piece is selected and a sizing of 1mm is defined and meshed

Analysis setting:

The analysis is set up for 14 steps with the following setting for all the steps.

When stabilizations is activated, it adds dampers to all the nodes. When the large displacement nodes try to move, the force is added to balance them thus favouring convergence. Energy Dissipations Ratio is given value between 0 and 1

Boundary conditions

• Both the side of work piece are selected and given a displacement of 90 mm in negative Y-axis direction.
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• The two roller are given 195 degree rotation in 14 steps , the directional of rotation of roller is opposite for each other
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Solutions:

All the necessary output variable are selected such as von Mesis stress, stress intensity, equivalent strain etc.

Equivalent stress:

The wheels were modeled as rigid bodies, but still it is possible to obtain a reasonable estimate of its normal stress (negligible shear stress) from the normal pressure acting on it at the contact.

The materials and the geometry of the roller should be able to function at such high contact pressures

The stress increases as the work piece enter the region between the roller and then decreases to a contact value as the work piece moves out of the rollers

Equivalent plastic strain:

In this case the plastic strain is of much significance as the work pieces is made to undergo deformation

Directional deformations (z-dir)

workpiece has displaced by 90mm

Conclusion

Overall, the structural analysis to simulate the rolling operations on a copper workpiece of length 90 mm is performed

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