The Finite Element Analysis Of Open Mill Roller And Its Optimization Design

With the development of technology and the improvement of people’s living standards, the growing use of rubber products in everyday life. Especially the rapid development of automobile industry has promoted the growing of tire industry, which created an opportunity for the rapid development of rubber-plastic machinery. Roller as the main component and the largest bearing capacity component of open mill, its safe and reliability play an important role in the process of mixing. The finite element analysis and optimal design of open mill roller to reduce quality、save material and energy will bring economic benefits based on the huge quantity of open mill, which also tally with the national policy of energy-saving and emission-reduction.The reporter subject to a typical0550×1600open mill roller, having a finite element analysis of roller on the platform of numerical simulation software ANSYS. Firstly having a steady-thermal analysis to know the distribution of temperature and thermal-stress, the distribution is that the thermal-stress along the roller radial become large to small and then large, while the compressive stress outer of the roller wall and the tensile stress inner of the roller wall. We can know the change of the transient-thermal stress, which first focused on the shaft-head, then gradually moves to the roller cylinder wall, similar to the steady-state thermal stress distribution of roller at last.Secondly, it is necessary to have a coupled analysis to analyze the stress of roller accurately, which is combined with under the action of mechanical stress and thermal stress. The max-stress is15.8Mpa and the max-strain is0.000139m after couple analysis, compare them with allowable deflection strain and material allowable stress we can know the roller have a lot of room for optimization.Thirdly, making a optimal design by defining volume as objective function、allowable stress and allowable deflection as state variable and inner diameter as design variable through the APDL, we can obtain a set of optimized, which show the optimized roller saving0.09862m3cast of material、easing28.87percent of volume and reducing715kg weight of roller, it prove that the influence of optimize effect is significant. Utilizing the Prob-module of ANSYS to make a reliability verification for the optimization model of roller, which pointed out that the failure rate of deflection and equivalent stress is0.79% and17.27%when the sampling frequency is200and the confidence level is95%. Obviously, if the sampling frequency increased the reliability will be increased accordingly.After all, the finite element and optimization analysis of roller is putting the advanced design and analyze method in the actual design, which provide a new idea for the design of economical, reliable and stable open mill, and also provide reference for the design of similar products at the same time.