Week 4- Rolling operation

Objective:

Simulate rolling operation of Copper Alloy workpiece to study various result outputs like Equivalent stress for the whole setup, Equivalent Plastic strain for the workpiece, Directional Deformation in the Z axis for the workpiece.

Analysis Setup:

1. Analysis System: Static Structural
2. Material Properties:

• Workpiece – Copper Alloy NL
• Rollers – Structural Steel

3. Mesh:
   1. Body sizing of 4 mm to Workpiece

4. Analysis Setting

No of Steps: 14

Large Deformation: ON

Energy Stabilization: Constant

Energy Dissipation: 0.1

5. Displacement Condition
   1. Workpiece: X and Y directions are free and displacement in Y direction is applied in 14 steps to side faces of workpiece (-3, -10, -17, -24, -31, -38, -45, -52, -60, -68, -75, -80, -85, -90)

6. Joints

• Cylindrical Joint is given on inner faces of rollers. And rotation is given in 14 steps as ( -7,-15,-30,-45,-60,-75,-90,-105,-120,-135,-150,-165,-180,-195)

Results Plots:

Results	Plots
Equivalent stress for the whole setup
Equivalent Plastic strain for the workpiece
Directional Deformation in the Z axis for the workpiece
Directional Deformation in the Y axis for the workpiece

Conclusion:

Sr. No	Results Plot	Values
1	Equivalent stress for the whole setup (Mpa)	2922.6
2	Equivalent Plastic strain for the workpiece	1.7814
3	Directional Deformation in the Z axis for the workpiece	-7.3694
4	Directional Deformation in the Y axis for the workpiece	-90

1. Directional Deformation in Y direction of the workpiece is indicating that workpiece has displaced by 90mm.
2. Value of Eq. Plastic Strain for the workpiece is 1.7814 & it indicate that workpiece is going under permanent deformation.
3. Directional Deformation along Z direction is indicating deformation of the workpiece after rolling operation and after rolling process workpiece is deform by almost -7.3694 mm in one side and other side is deform by 6.18 mm.
4. Overall equivalent stress generated is 2922.6 Mpa.