Week 4- Rolling operation

Objective:

For this challenge, we will have to simulate the rolling operation on a workpiece made of copper.  Increase the length of the workpiece by 60mm and decrease its size on both sides by 8mm. Run the simulation for 14 steps . Ensure that the edge of the workpiece is displaced by 90mm.

Find out the

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 displaced by 90mm

Procedure:

• Go to static structural <rename Rolling copper
• add copper alloy NL to the library 
• import geometry<edit in space claim pull 60mm height and reduce the width 8mm each side
• update the model
• go to model <edit <mechanical APDL will open

Creating contacts:

• go to contacts<select two contacts<select rename based on definition<for first contact select contact as roller 1 and target workpiece top face
• for second contact select contact roller2 and target workpiece bottom face
• select two contacts <type=frictional<frictional coefficient is 0.2

• 
• formulation=augmented lagrange<normal stiffness=factor i.e 0.1<update stiffness=each iteration<interface treatment=Add offset and ramped effects

creating joints:

• go to connections<insert<joint<type cylindrical<scoping method=select inner surface of the roller1<direction is z
• same way create another joint with roller2

Meshing:

• go to meshing <insert <sizing<select work piece and <element size is 4mm
• generate the mesh

• Go analysis settings<select no of steps =14<select all steps by using shift key<large deflection is on

• go to static structural<insert<displacement<geometry=select work piece<defined by components<y component =Tabular data

joint loads:

• go to static structural<insert<joint load<joint=select 1st joint<dof=rotation z<type=rotation<magnitude tabular data

• same way create another joint load for roller2 in opposite direction 

requesting results:

go to solution<right click <select equivalent stress for whole setup,equivalent plastic strain for work piece,directional deformation for work piece in zdirection,directional deformation of work piece in ydirection.

Results:

Equivalent stress:

Directional deformation:

Equivalent plastic strain:

Distance travelled by workpiece:

Conclussions:

• In rolling operation of copper alloy work piece produce maximum amount of stress is 3298.8 Mpa
• maximum directional deformation of workpiece in zdirection is 10.73mm
• maximum plastic strain in workpiece is 2.132
• the workpiece travelled a distance of 90mm