Week 4- Rolling operation

OBJECTIVE:-

To simulate the rolling operation on a workpiece made of copper and to evaluate the following results:

1. Equivalent stress for the whole setup
2. Equivalent Plastic strain for the workpiece
3. Directional Deformation in the Z-axis for the workpiece
4. Prove that the workpiece has been displaced by 90mm

GEOMETRY:-

The provided geometry was imported into SpaceClaim and its length was increased by 60mm and the width was decreased by 8mm on both sides.

MATERIAL:-

Copper NL is used for workpiece & structural steel is used for rollers

Setting up the contact:

Frictional contact is set between workpiece and rollers

friction coefficient as 0.2

normal stiffness factor is 0.1

update stiffness: Each iteration

Interference treatment: set offset, ramped effects

Joints:-

Two joints were created for two wheels with a connection type of Body-ground.

Mesh:-

Body sizing set to program controlled

3 mm sizing assigned for workpiece

Analysis settings:-

The simulation was performed in 14 steps assigning gradual displacement to the workpiece and rotation of wheel assigned approximately with the difference of 15 degrees

Rotation assigned:-

Displacement assigned:-

Results:-

Total Stress considering entire geometry

Stress considering workpiece:

Total strain:

2 Equivalent Elastic strain for the workpiece:

3 Directional Deformation in the Z-axis for the workpiece:

4 Prove that the workpiece has displaced by 90mm :

We can see the workpiece is displaced by 90.5 mm as we can see in the deformation plot

Conclusion:-

The simulation was performed successfully

• Equivalent stress on a plate of 8467.6 MPa
• Strain considering entire geometry 0.038731.
• Directional deforamtion z axis 7.8719mm
• The plate was displaced by 90mm proven.