Reply To: Mesh convergence more mesh get lower stress

[Kaushal Vadnere]

So, from what I understand, the upper roller does not play any significant role in rolling of the the plate. so you can maybe suppress that to save the solution time.

The reason your plate goes in backwards direction is because you've not constrained it. You need to add a support (possibly a fixed support at the bottom of the plate). Refer to this free Anys Course on how to appropriately select boundary condition to match real life scenario: Structural Boundary Conditions | Ansys Innovation Courses

For Contacts, try using augmented lagrange with asymmetric behaviour and contact detection method "Nodal-Projected Normal from Contact". Make sure you have scoped the roller as contact side and plate as target. Also, try to keep element size for contact and target similar (you can define local element sizing on the roller surface). Refer to these free Ansys Innovation Courses to learn more about best practices in contacts: Fundamental Topics in Contact | Ansys Innovation Courses, Rigid Body Motion in Contact | Ansys Innovation Courses.