Week 4- Rolling operation

Aim : To simulate rolling operation on copper workpiece and determine Equivalent stress for the whole setup , directional deformation and Equivalent plastic strain for the workpiece. 

Procedure :

• Geometry selection :
  1. Geometry was imported on space claim, length of the workpiece was increased by 60 mm , width was decreased vy 8 mm from both the sides.
  2. Each component of the model were named accordingly.
• Contact :
  1. Frictional contact were defined between the workpiece and the both the rollers .
      Frictional coefficient : 0.2
      Formulation : Augmented Lagrange .
      Normal stiffness factor : 0.1
• Joints :
  Cylindrical joints were defined for both the rollers , with rotation along z axis .
• Mesh :
  Body sizing for the element was defined , 2mm.

• Analysis settings :
  1. Total displacement of 90 mm was defined for the work piece in 14 steps along negative y axis.
  2. Total roation of 210 degrees was applied to the rollers , clockwise direction for upper roller , counterclockwise direction for lower roller along z axis.

Results :

1. Equivalent stress for the whole setup :

Equivalent stress for the whole setup = 3047.1 MPa

2. Equivalent plastic strain for the workpiece :

Equivalent Plastic strain for the workpiece = 1.6536 mm/mm

3. Directional deformation in z axis :

Directional Deformation in z axis	Maximum	Minimum
Workpiece	27.248	-3.6853

4. Workpiece Displacement :

From the above figure , maximum displacement in Y direction is - 90 mm (-90.808+0.7) , hence it is stated that the workpiece is displaced by 90 mm total.

Result :

Rolling operation was simulated on Ansys workbench for copper workpiece and Equivalent stress , equivalent plastic strain & Directional deformation were found for the setup and the workpiece as follows :

Property	Object	Maximum	Minimum
Equivalent Stress (Mpa)	Whole setup	3047.1	/
Equivalent Plastic Strain	Workpiece	1.6536	0.0006
Directional Deformation	Workpiece	27.248	-3.6853